Method of Making Polymer Ammunition Cartridge Having a Two-Piece Primer Insert

ABSTRACT

The present invention provides ammunition cartridge having a two piece primer insert with a flange, a polymeric middle body extending from the primer insert to a cylindrical middle body coupling region, and a polymeric projectile end having a projectile aperture mated to the polymeric middle body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation application of U.S. patentapplication Ser. No. 16,377,799 filed Apr. 8, 2019, which is aContinuation application of U.S. patent application Ser. No. 16/123,242filed Sep. 6, 2018, now U.S. Pat. No. 10,302,404, which is aContinuation application of U.S. patent application Ser. No. 15/959,657filed Apr. 23, 2018, now U.S. Pat. No. 10,302,403, which is aContinuation application of U.S. patent application Ser. No. 15/801,837filed Nov. 2, 2017, now U.S. Pat. No. 9,976,840, which is a Continuationapplication of U.S. patent application Ser. No. 15/064,807, filed Mar.9, 2016, now U.S. Pat. No. 9,835,427, the contents of which are allincorporated by reference herein in their entirety.

TECHNICAL FIELD OF THE INVENTION

The present invention relates in general to the field of ammunition,specifically to polymer ammunition cartridges having a primer insertsmade by joining 2 or more portions.

STATEMENT OF FEDERALLY FUNDED RESEARCH

Not Applicable.

INCORPORATION-BY-REFERENCE OF MATERIALS FILED ON COMPACT DISC

Not Applicable.

BACKGROUND OF THE INVENTION

Without limiting the scope of the invention, its background is describedin connection with lightweight polymer cartridge casing ammunition.Conventional ammunition cartridge casings for rifles and machine guns,as well as larger caliber weapons, are made from brass, which is heavy,expensive, and potentially hazardous. There exists a need for anaffordable lighter weight replacement for brass ammunition cartridgecases that can increase mission performance and operationalcapabilities. Lightweight polymer cartridge casing ammunition must meetthe reliability and performance standards of existing fielded ammunitionand be interchangeable with brass cartridge casing ammunition inexisting weaponry. Reliable cartridge casings manufacturing requiresuniformity (e.g., bullet seating, bullet-to-casing fit, casing strength,etc.) from one cartridge to the next in order to obtain consistentpressures within the casing during firing prior to bullet and casingseparation to create uniformed ballistic performance. Plastic cartridgecasings have been known for many years but have failed to providesatisfactory ammunition that could be produced in commercial quantitieswith sufficient safety, ballistic, handling characteristics, and survivephysical and natural conditions to which it will be exposed during theammunition's intended life cycle; however, these characteristics havenot been achieved.

For example, U.S. Pat. No. 7,441,504 discloses a base for a cartridgecasing body for an ammunition article, the base having an ignitiondevice; an attachment device at one end thereof, the attachment devicebeing adapted to the base to a cartridge casing body; wherein the baseis made from plastic, ceramic, or a composite material.

U.S. Pat. No. 7,610,858 discloses an ammunition cartridge assembled froma substantially cylindrical polymeric cartridge casing body; and acylindrical polymeric middle body component with opposing first andsecond ends, wherein the first end has a coupling element that is a matefor the projectile-end coupling element and joins the first end of themiddle body component to the second end of the bullet-end component, andthe second end is the end of the casing body opposite the projectile endand has a male or female coupling element; and a cylindrical cartridgecasing head-end component with an essentially closed base end with aprimer hole opposite an open end with a coupling element that is a matefor the coupling element on the second end of the middle body and joinsthe second end of the middle body component to the open end of thehead-end component.

Shortcomings of the known methods of producing plastic or substantiallyplastic ammunition include the possibility of the projectile beingpushed into the cartridge casing, the bullet pull being too light suchthat the bullet can fall out, the bullet pull being too insufficient tocreate sufficient chamber pressure, the bullet pull not being uniformfrom round to round, and portions of the cartridge casing breaking offupon firing causing the weapon to jam or damage or danger whensubsequent rounds are fired or when the casing portions themselvesbecome projectiles. To overcome the above shortcomings, improvements incartridge case design and performance polymer materials are needed.

BRIEF SUMMARY OF THE INVENTION

The present invention provides an ammunition cartridge having a twopiece primer insert comprising: a two piece primer insert (32)comprising: an upper primer insert portion (56) connected to a lowerprimer insert portion (58), wherein the upper primer insert portion (56)comprises an upper primer bottom surface (34), an upper primer aperture(33) through the upper primer bottom surface (34), and a substantiallycylindrical coupling element (30) extending away from the upper primerbottom surface (34), wherein the lower primer insert portion (58)comprises: a lower primer bottom surface (35) opposite a lower primertop surface (36), a primer recess (38) in the lower primer top surface(36) that extends toward the lower primer bottom surface (35) andadapted to fit a primer, a lower flash hole aperture (37) through thelower primer bottom surface (35), wherein the lower flash hole aperture(37) is larger than the upper primer aperture (33) to form a flash holegroove (39) in the primer recess (38); a polymeric middle body extendingfrom a middle body coupling region over the two piece primer insert andinto the flash hole groove to form a flash hole, wherein the polymericmiddle body comprises a first polymer; a polymeric nose portioncomprising a nose coupler connected to the middle body coupling region,a shoulder extending from the nose coupler, a neck extending from theshoulder and a projectile aperture in the neck, wherein the nose portioncomprises a second polymer; and a propellant chamber defined between theflash hole and the projectile aperture. The two piece primer insert mayinclude a primer flash aperture groove positioned in the primer recessaround the primer flash aperture and the first polymer compositionextends into the primer flash aperture to form a flash hole. The firstpolymer composition, the second polymer composition or both comprise anylon polymer. The first polymer composition, the second polymercomposition or both comprise a fiber-reinforced polymeric compositee.g., between about 10 and about 70 wt % glass fiber fillers, mineralfillers, or mixtures thereof. The bullet aperture may include one ormore cannelures formed on an inner circumferential surface of the bulletaperture. The substantially cylindrical coupling region and thepolymeric bullet-end coupling may be welded or bonded together. Thefirst polymer composition, the second polymer composition or both may bepolyurethane prepolymer, cellulose, fluoro-polymer, ethyleneinter-polymer alloy elastomer, ethylene vinyl acetate, nylon, polyetherimide, polyester elastomer, polyester sulfone, polyphenyl amide,polypropylene, polyvinylidene fluoride or thermoset polyurea elastomer,acrylics, homopolymers, acetates, copolymers,acrylonitrile-butadinen-styrene, thermoplastic fluoro polymers, inomers,polyamides, polyamide-imides, polyacrylates, polyatherketones,polyaryl-sulfones, polybenzimidazoles, polycarbonates, polybutylene,terephthalates, polyether imides, polyether sulfones, thermoplasticpolyimides, thermoplastic polyurethanes, polyphenylene sulfides,polyethylene, polypropylene, polysulfones, polyvinylchlorides, styreneacrylonitriles, polystyrenes, polyphenylene, ether blends, styrenemaleic anhydrides, polycarbonates, allyls, aminos, cyanates, epoxies,phenolics, unsaturated polyesters, bismaleimides, polyurethanes,silicones, vinylesters, urethane hybrids, polyphenylsulfones, copolymersof polyphenylsulfones with polyethersulfones or polysulfones, copolymersof poly-phenylsulfones with siloxanes, blends of polyphenylsulfones withpolysiloxanes, poly(etherimide-siloxane) copolymers, blends ofpolyetherimides and polysiloxanes, and blends of polyetherimides andpoly(etherimide-siloxane) copolymers. The projectile may be a 223,0.243, 0.25-06, 0.270, 0.300, 0.308, 0.338, 0.30-30, 0.30-06, 0.45-70 or0.50-90, 50 caliber, 45 caliber, 380 caliber or 38 caliber, 5.56 mm, 6mm, 7 mm, 7.62 mm, 8 mm, 9 mm, 10 mm, 12.7 mm, 14.5 mm, 14.7 mm, 20 mm,25 mm, 30 mm, 40 mm, 57 mm, 60 mm, 75 mm, 76 mm, 81 mm, 90 mm, 100 mm,105 mm, 106 mm, 115 mm, 120 mm, 122 mm, 125 mm, 130 mm, 152 mm, 155 mm,165 mm, 175 mm, 203 mm or 460 mm, 4 inch, 4.2 inch or 8 inch. Theprojectile may have a frustoconical shaped nose. The frustoconical shapemay be a cavity to form a hollow point projectile. The projectile mayhave a spritzer shaped nose and/or a boattail shaped base. The upperprimer insert portion, the lower primer insert portion or both may beindependently formed by metal injection molding, polymer injectionmolding, stamping, milling, molding, machining, punching, fine blanking,smelting, or any other method that will form insert portions that may bejoined together to form a primer insert. The upper primer insertportion, the lower primer insert portion or both independently comprisesa polymer, a metal, an alloy, or a ceramic alloy. The ammunition ofclaim 4, wherein the upper primer insert portion and the lower primerinsert portion may be made of the same material or different materials.A flash hole groove may extend circumferentially about the upper primeraperture or the lower primer aperture.

The present invention includes an ammunition cartridge having a threepiece primer insert comprising: an upper primer insert portioncomprising an upper primer bottom surface opposite an upper primer topsurface, an upper primer aperture through the upper primer bottomsurface and the an upper primer top surface; a flash hole groove thatextends circumferentially about the upper primer aperture on the upperprimer bottom surface, a substantially cylindrical coupling elementextending away from the upper primer top surface, and an interiorsurface inside the substantially cylindrical coupling element; a lowerprimer insert portion comprising a lower primer bottom surface oppositea lower primer top surface, a primer recess in the lower primer topsurface that extends toward the lower primer bottom surface and adaptedto fit a primer, and a lower primer aperture through the lower primerbottom surface; an insert joint that links the upper primer bottomsurface and the lower primer bottom surface to align the lower primeraperture and form a primer insert; a flange portion comprising a flangetop surface opposite a flange bottom surface, a flange primer apertureextending from the flange top surface to the flange bottom surface, anda flange that extends circumferentially about an outer edge of theflange bottom surface, wherein the flange is adapted to receive apolymer overmolding; and a flange joint that links the flange bottomsurface and the lower primer bottom surface to align the flange primeraperture and the lower primer aperture to form a primer insert, whereinthe insert joint is smelted, sintered, adhesive bonded, laser welded,ultrasonic welded, friction spot welded, or friction stir welded,wherein the flange joint is smelted, sintered, adhesive bonded, laserwelded, ultrasonic welded, friction spot welded, and friction stirwelded, wherein the upper primer insert portion, the lower primer insertportion or both independently formed by metal injection molding, polymerinjection molding, stamping, milling, molding, machining, punching, fineblanking, smelting, or any other method that will form insert portionsthat may be joined together to form a primer insert; a substantiallycylindrical polymeric middle body extending from the substantiallycylindrical primer insert to a cylindrical middle body coupling regionmolded from a first polymer, wherein the first polymer is molded overthe flange, the inner circumferential surface and the outer surface andextends to the cylindrical middle body coupling region; a substantiallycylindrical polymeric projectile end mated to the substantiallycylindrical polymeric middle body, wherein the substantially cylindricalpolymeric projectile end comprises a projectile end coupling region thatextends to a shoulder region that reduces to a neck region having aprojectile aperture wherein the projectile end coupling region couplesto the middle body coupling region; and a propellant chamber definedbetween the primer flash aperture and the projectile aperture.

The present invention includes an ammunition cartridge having a twopiece primer insert comprising: a two piece insert comprising: an upperprimer insert portion comprising an upper primer bottom surface, anupper primer aperture through the upper primer bottom surface; asubstantially cylindrical coupling element extending away from the upperprimer bottom surface, and an interior surface inside the substantiallycylindrical coupling element; a lower primer insert portion comprising alower primer bottom surface opposite a lower primer top surface, a flashhole groove that extends circumferentially about the upper primeraperture or the lower primer aperture, and the first polymer compositionextends into the primer flash aperture to form a flash hole, a primerrecess in the lower primer top surface that extends toward the lowerprimer bottom surface and adapted to fit a primer, a lower primeraperture through the lower primer bottom surface, and a flange thatextends circumferentially about an outer edge of the lower primer topsurface, wherein the flange is adapted to receive a polymer overmolding;and an insert joint that links the upper primer bottom surface and thelower primer bottom surface to align the lower primer aperture and forma primer insert; a substantially cylindrical polymeric middle bodyextending from the substantially cylindrical primer insert to acylindrical middle body coupling region molded from a first polymer,wherein the first polymer is molded over the flange, the innercircumferential surface and the outer surface and extends to thecylindrical middle body coupling region; a substantially cylindricalpolymeric projectile end mated to the substantially cylindricalpolymeric middle body, wherein the substantially cylindrical polymericprojectile end comprises a projectile end coupling region that extendsto a shoulder region that reduces to a neck region having a projectileaperture wherein the projectile end coupling region couples to themiddle body coupling region; and a propellant chamber defined betweenthe primer flash aperture and the projectile aperture.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a more complete understanding of the features and advantages of thepresent invention, reference is now made to the detailed description ofthe invention along with the accompanying figures and in which:

FIG. 1 depicts a side, cross-sectional view of a polymeric cartridgecase according to one embodiment of the present invention;

FIG. 2 depicts a side, cross-sectional view of a portion of thepolymeric cartridge case according to one embodiment of the presentinvention;

FIG. 3 depicts a side, cross-sectional view of a portion of thepolymeric cartridge case having a two piece primer insert.

FIG. 4 depicts a side, cross-sectional view of a portion of thepolymeric cartridge case having a two piece primer insert and adiffuser.

FIGS. 5A-5H depict different embodiment of the diffuser of the presentinvention.

FIGS. 6A-6D depicts a side, cross-sectional view of a two piece primerinsert used in a polymeric cartridge case.

FIGS. 7A-7B depicts a side, cross-sectional view of a stamped two pieceprimer insert used in a polymeric cartridge case.

FIGS. 8A-8C depicts a side, cross-sectional view of a two piece primerinsert having a tab and groove configuration used in a polymericcartridge case.

FIGS. 9A-9B depicts a side, cross-sectional view of a three piece primerinsert configuration used in a polymeric cartridge case.

FIG. 10 depicts a perspective view of a two piece primer insert used ina polymeric cartridge case.

DETAILED DESCRIPTION OF THE INVENTION

While the making and using of various embodiments of the presentinvention are discussed in detail below, it should be appreciated thatthe present invention provides many applicable inventive concepts thatcan be embodied in a wide variety of specific contexts. The specificembodiments discussed herein are merely illustrative of specific ways tomake and use the invention and do not delimit the scope of theinvention.

Reliable cartridge manufacture requires uniformity from one cartridge tothe next in order to obtain consistent ballistic performance. Amongother considerations, proper bullet seating and bullet-to-casing fit isrequired. In this manner, a desired pressure develops within the casingduring firing prior to bullet and casing separation. Historically,bullets employ a cannelure, which is a slight annular depression formedin a surface of the bullet at a location determined to be the optimalseating depth for the bullet. In this manner, a visual inspection of acartridge could determine whether or not the bullet is seated at theproper depth. Once the bullet is inserted into the casing to the properdepth, one of two standard procedures is incorporated to lock the bulletin its proper location. One method is the crimping of the entire end ofthe casing into the cannelure. A second method does not crimp the casingend; rather the bullet is pressure fitted into the casing.

The polymeric ammunition cartridges of the present invention are of acaliber typically carried by soldiers in combat for use in their combatweapons. The present invention is not limited to the described caliberand is believed to be applicable to other calibers as well. Thisincludes various small and medium caliber munitions, including 5.56 mm,7.62 mm, 308, 338, 3030, 3006, and 0.50 caliber ammunition cartridges,as well as medium/small caliber ammunition such as 380 caliber, 38caliber, 9 mm, 10 mm, 20 mm, 25 mm, 30 mm, 40 mm, 45 caliber and thelike. The projectile and the corresponding cartridge may be of anydesired size, e.g., 0.223, 0.243, 0.25-06, 0.270, 0.300, 0.308, 0.338,0.30-30, 0.30-06, 0.45-70 or 0.50-90, 50 caliber, 45 caliber, 380caliber or 38 caliber, 5.56 mm, 6 mm, 7 mm, 7.62 mm, 8 mm, 9 mm, 10 mm,12.7 mm, 14.5 mm, 14.7 mm, 20 mm, 25 mm, 30 mm, 40 mm, 57 mm, 60 mm, 75mm, 76 mm, 81 mm, 90 mm, 100 mm, 105 mm, 106 mm, 115 mm, 120 mm, 122 mm,125 mm, 130 mm, 152 mm, 155 mm, 165 mm, 175 mm, 203 mm or 460 mm, 4.2inch or 8 inch. The cartridges, therefore, are of a caliber betweenabout 0.05 and about 5 inches. Thus, the present invention is alsoapplicable to the sporting goods industry for use by hunters and targetshooters.

The present invention includes primer inserts that are made as amulti-piece insert. In one embodiment the multi-piece insert is a 2piece insert but may be a 3, 4, 5, or 6 piece insert. Regardless of thenumber of pieces the multi-piece insert each piece may be of similar ordissimilar materials that are connected to form a unitary primer insert.The portions of the primer insert may be constructed from dissimilarmaterials including metal-to-metal, polymer-to-polymer andmetal-to-polymer joints. The individual pieces may be joined usingvarious methods including smelting, sintering, adhesive bonding, weldingtechniques that joining dissimilar materials, including laser welding,ultrasonic welding, friction spot welding, and friction stir welding.The method of connecting the individual pieces to form a unitary insertwill depend on the materials being joined. For example, a metal insertmay is constructed from 2 or more metal pieces with similar meltingpoints are joined together to form a unitary insert through sintering.

The substantially cylindrical primer insert 32 includes at least anupper primer insert portion 56 and a lower primer insert portion 58joined at insert joint 60. Although, there can be 3, 4, 5, 6, or moreportions. In addition the portions may be in the vertical axis insteadof the horizontal axis as shown in the figures. For example, theinterior portion may be a first portion, the outer portion a secondportion and the lower section may be a third portion, and the outerportion a fourth portion.

Regardless of the number of section each portion may be made from asingle material that is milled, stamped, forged, machined, molded, castor other method of forming a primer insert portion.

FIG. 1 depicts a side, cross-sectional view of a portion of a polymericcartridge case having a two piece primer insert. A cartridge 10 is shownmanufactured with a polymer casing 12 showing a propellant chamber 14with projectile aperture at the forward end opening 16. The polymercasing 12 has a substantially cylindrical open-ended polymericbullet-end 18 extending from forward end opening 16 rearward to oppositeend 20. The bullet-end component 18 may be formed with the coupling end22 formed on the end 20. The coupling end 22 is shown as a femaleelement, but may also be configured as a male element in alternateembodiments of the invention. The forward end of bullet-end component 18has a shoulder 24 forming chamber neck 26. The bullet-end componenttypically has a wall thickness between about 0.003 and about 0.200inches; more preferably between about 0.005 and about 0.150; and morepreferably between about 0.010 and about 0.050 inches.

The middle body component 28 is connected to a substantially cylindricalcoupling element 30 of the substantially cylindrical insert 32. Thecoupling element 30, as shown may be configured as a male element,however, all combinations of male and female configurations isacceptable for the coupling elements 30 and the coupling end 22 inalternate embodiments of the invention. The coupling end 22 ofbullet-end component 18 fits about and engages the coupling element 30of a substantially cylindrical insert 32.

The substantially cylindrical primer insert 32 has an upper primerinsert portion 56 and a lower primer insert portion 58 joined at insertjoint 60. The upper primer insert portion 56 may be of the same ordifferent materials than lower primer insert portion 58. The insertjoint 60 mates the upper primer insert portion 56 and the lower primerinsert portion 58 while retaining the primer flash hole 40. The insertjoint 60 mates the upper primer insert portion 56 and the lower primerinsert portion 58 by welding or bonding using solvent, adhesive,spin-welding, vibration-welding, ultrasonic-welding or laser-weldingtechniques. In addition multiple methods may be used to increases thejoint strength. The upper primer insert portion 56 includes asubstantially cylindrical coupling element 30 extending from a bottomsurface 34 that is opposite a top surface 36. Located in the top surface36 is a primer recess 38 that extends toward the bottom surface 34. Aprimer flash hole 40 is located in the primer recess 38 and extendsthrough the bottom surface 34 into the propellant chamber 14. Thecoupling end 22 extends the polymer through the primer flash hole 40 toform an aperture coating 42 while retaining a passage from the topsurface 36 through the bottom surface 34 and into the propellant chamber14 to provide support and protection about the primer flash hole 40.When contacted the coupling end 22 interlocks with the substantiallycylindrical coupling element 30, through the coupling element 30 thatextends with a taper to a smaller diameter at the tip 44 to form aphysical interlock between substantially cylindrical insert 32 andmiddle body component 28. The polymer casing 12 also has a substantiallycylindrical open-ended middle body component 28. The middle bodycomponent extends from a forward end opening 16 to the coupling element22. The middle body component typically has a wall thickness betweenabout 0.003 and about 0.200 inches; and more preferably between about0.005 and about 0.150 inches; and more preferably between about 0.010and about 0.050 inches. The bullet-end 16, middle body 18 and bottomsurface 34 define the interior of propellant chamber 14 in which thepowder charge (not shown) is contained. The interior volume of thepropellant chamber 14 may be varied to provide the volume necessary forcomplete filling of the chamber 14 by the propellant chosen so that asimplified volumetric measure of propellant can be utilized when loadingthe cartridge. Either a particulate or consolidated propellant can beused. The lower primer insert portion 58 also has a flange 46 and aprimer recess 38 formed therein for ease of insertion of the primer (notshown). The primer recess 38 is sized so as to receive the primer (notshown) in an interference fit during assembly. A primer flash hole 40communicates through the bottom surface 34 of substantially cylindricalinsert 32 into the propellant chamber 14 so that upon detonation ofprimer (not shown) the powder (not shown) in propellant chamber 14 willbe ignited.

The projectile (not shown) is held in place within chamber case neck 26at forward opening 16 by an interference fit. Mechanical crimping of theforward opening 16 can also be applied to increase the bullet pull forceholding the bullet (not shown) in place. The bullet (not shown) may beinserted into place following the completion of the filling ofpropellant chamber 14. The projectile (not shown) can also be injectionmolded directly onto the forward opening 16 prior to welding or bondingtogether using solvent, adhesive, spin-welding, vibration-welding,ultrasonic-welding or laser-welding techniques. The welding or bondingincreases the joint strength so the casing can be extracted from the hotgun casing after firing at the cook-off temperature.

The bullet-end 18 and bullet components can then be welded or bondedtogether using solvent, adhesive, spin-welding, vibration-welding,ultrasonic-welding or laser-welding techniques. The welding or bondingincreases the joint strength so the casing can be extracted from the hotgun casing after firing at the cook-off temperature. An optional firstand second annular groove (cannelures) may be provided in the bullet-endin the interlock surface of the male coupling element to provide asnap-fit between the two components. The cannelures formed in a surfaceof the bullet at a location determined to be the optimal seating depthfor the bullet. The bullet is inserted into the casing to the depth tolock the bullet in its proper location. One method is the crimping ofthe entire end of the casing into the cannelures. The bullet-end andmiddle body components can then be welded or bonded together usingsolvent, adhesive, spin-welding, vibration-welding, ultrasonic-weldingor laser-welding techniques. The welding or bonding increases the jointstrength so the casing can be extracted from the hot gun casing afterfiring at the cook-off temperature.

FIG. 2 depicts a side, cross-sectional view of a portion of thepolymeric cartridge case having a two piece primer insert. Thesubstantially cylindrical primer insert 32 has an upper primer insertportion 56 and a lower primer insert portion 58 joined at insert joint60. The upper primer insert portion 56 may be of the same or differentmaterials than lower primer insert portion 58. The upper primer insertportion 56 mates to the lower primer insert portion 58 at insert joint60 while retaining the primer flash hole 40 and the primer recess 38.The insert joint 60 may connect the upper primer insert portion 56 andthe lower primer insert portion 58 by welding or bonding using solvent,adhesive, spin-welding, vibration-welding, ultrasonic-welding orlaser-welding techniques. In addition, multiple methods may be used toincrease the joint strength. The upper primer insert portion 56 includesa substantially cylindrical coupling element 30 extending from a bottomsurface 34 that is opposite a top surface 36. The coupling element 30extends with a taper to a smaller diameter at the tip 44. Located in thetop surface 36 is a primer recess 38 that extends toward the bottomsurface 34. A primer flash hole 40 is located in the primer recess 38and extends through the bottom surface 34 into the propellant chamber14. The coupling end 22 of the middle body extends the polymer throughthe primer flash hole 40 to form an aperture coating 42 while retaininga passage from the top surface 36 through the bottom surface 34 and intothe propellant chamber 14 to provide support and protection about theprimer flash hole 40. When over-molded the coupling end 22 interlockswith the substantially cylindrical coupling element 30. The couplingelement 30 extends with a taper to a smaller diameter at the tip 44 tophysical interlock the substantially cylindrical insert 32 to the middlebody component. The substantially cylindrical insert 32 includes asubstantially cylindrical coupling element 30 extending from a bottomsurface 34 that is opposite a top surface 36. Located in the top surface36 is a primer recess 38 that extends toward the bottom surface 34. Aprimer flash hole 40 is located in the primer recess 38 and extendsthrough the bottom surface 34 into the propellant chamber 14. Thecoupling end 22 extends the polymer through the primer flash hole 40 toform an aperture coating 42 while retaining a passage from the topsurface 36 through the bottom surface 34 and into the propellant chamber14 to provide support and protection about the primer flash hole 40.When contacted the coupling end 22 interlocks with the substantiallycylindrical coupling element 30, through the coupling element 30 thatextends with a taper to a smaller diameter at the tip 44 to physicalinterlock the substantially cylindrical insert 32 and the middle bodycomponent 28.

FIG. 3 depicts a side, cross-sectional view of a portion of thepolymeric cartridge case having a two piece primer insert. Thesubstantially cylindrical primer insert 32 has an upper primer insertportion 56 and a lower primer insert portion 58 joined at insert joint60. The upper primer insert portion 56 may be of the same or differentmaterials than lower primer insert portion 58. The upper primer insertportion 56 mates to the lower primer insert portion 58 at insert joint60 while retaining the primer flash hole 40 and the primer recess 38.The insert joint 60 may connect the upper primer insert portion 56 andthe lower primer insert portion 58 by welding or bonding using solvent,adhesive, spin-welding, vibration-welding, ultrasonic-welding orlaser-welding techniques. In addition, multiple methods may be used toincrease the joint strength. The upper primer insert portion 56 includesa substantially cylindrical coupling element 30 extending from a bottomsurface 34 that is opposite a top surface 36. The coupling element 30extends with a taper to a smaller diameter at the tip 44. Located in thetop surface 36 is a primer recess 38 that extends toward the bottomsurface 34. A primer flash hole 40 is located in the primer recess 38and extends through the bottom surface 34 into the propellant chamber14. The coupling end 22 of the middle body extends the polymer up to theprimer flash hole 40 while retaining a passage from the top surface 36through the bottom surface 34 and into the propellant chamber 14. Whenover-molded the coupling end 22 interlocks with the substantiallycylindrical coupling element 30. The coupling element 30 extends with ataper to a smaller diameter at the tip 44 to physical interlock thesubstantially cylindrical insert 32 to the middle body component. Thesubstantially cylindrical insert 32 includes a substantially cylindricalcoupling element 30 extending from a bottom surface 34 that is oppositea top surface 36. Located in the top surface 36 is a primer recess 38that extends toward the bottom surface 34. A primer flash hole 40 islocated in the primer recess 38 and extends through the bottom surface34 into the propellant chamber 14. The coupling end 22 extends thepolymer through the primer flash hole 40 to form an aperture coating 42while retaining a passage from the top surface 36 through the bottomsurface 34 and into the propellant chamber 14 to provide support andprotection about the primer flash hole 40. When contacted the couplingend 22 interlocks with the substantially cylindrical coupling element30, through the coupling element 30 that extends with a taper to asmaller diameter at the tip 44 to physical interlock the substantiallycylindrical insert 32 and the middle body component 28.

FIG. 4 depicts a side, cross-sectional view of a portion of thepolymeric cartridge case having a two piece primer insert and adiffuser. The substantially cylindrical primer insert 32 has an upperprimer insert portion 56 and a lower primer insert portion 58 joined atinsert joint 60. The upper primer insert portion 56 may be of the sameor different materials than lower primer insert portion 58. The upperprimer insert portion 56 mates to the lower primer insert portion 58 atinsert joint 60 while retaining the primer flash hole 40 and the primerrecess 38. The insert joint 60 may connect the upper primer insertportion 56 and the lower primer insert portion 58 by welding or bondingusing solvent, adhesive, spin-welding, vibration-welding,ultrasonic-welding or laser-welding techniques. In addition, multiplemethods may be used to increase the joint strength. The upper primerinsert portion 56 includes a substantially cylindrical coupling element30 extending from a bottom surface 34 that is opposite a top surface 36.The coupling element 30 extends with a taper to a smaller diameter atthe tip 44. Located in the top surface 36 is a primer recess 38 thatextends toward the bottom surface 34. A primer flash hole 40 is locatedin the primer recess 38 and extends through the bottom surface 34 intothe propellant chamber 14. The coupling end 22 of the middle bodyextends the polymer through the primer flash hole 40 to form an aperturecoating 42 while retaining a passage from the top surface 36 through thebottom surface 34 and into the propellant chamber 14 to provide supportand protection about the primer flash hole 40. When over-molded thecoupling end 22 interlocks with the substantially cylindrical couplingelement 30. The coupling element 30 extends with a taper to a smallerdiameter at the tip 44 to physical interlock the substantiallycylindrical insert 32 to the middle body component. The substantiallycylindrical insert 32 includes a substantially cylindrical couplingelement 30 extending from a bottom surface 34 that is opposite a topsurface 36. Located in the top surface 36 is a primer recess 38 thatextends toward the bottom surface 34. A primer flash hole 40 is locatedin the primer recess 38 and extends through the bottom surface 34 intothe propellant chamber 14. The coupling end 22 extends the polymerthrough the primer flash hole 40 to form an aperture coating 42 whileretaining a passage from the top surface 36 through the bottom surface34 and into the propellant chamber 14 to provide support and protectionabout the primer flash hole 40. When contacted the coupling end 22interlocks with the substantially cylindrical coupling element 30,through the coupling element 30 that extends with a taper to a smallerdiameter at the tip 44 to physical interlock the substantiallycylindrical insert 32 and the middle body component 28. The diffuser 50includes a diffuser aperture 52 and a diffuser aperture extension 54that aligns with the primer flash hole 40. The diffuser 50 diverts thecombustion effect away from the over-molded polymer material of themiddle body component 28. The affects being the impact from igniting theprimer as far as pressure and heat to divert the energy of the primeroff of the polymer and directing it to the flash hole. The diffuser 50can be between 0.004 to 0.010 inches (e.g., 0.0001, 0.0002, 0.0003,0.0004, 0.0005, 0.0006, 0.0007, 0.0008, 0.0009, 0.001, 0.002, 0.003,0.004, 0.005, 0.006, 0.007, 0.008, 0.009, 0.010, 0.011, 0.012, 0.013,0.014, or 0.015) in thickness and made from metal, polymer, composite,or other material, e.g., half hard brass. For example, the diffuser 50can be between about 0.005 inches thick for a 5.56 diffuser 50. Theouter diameter of the diffuser for a 5.56 or 223 case is 0.173 and theinner diameter is 0.080. The diffuser could be made of any material thatcan withstand the energy from the ignition of the primer, e.g., alloys,metals, steel, stainless, cooper, aluminum, resins and polymers. Thediffuser 50 can be produce in “T”, ‘L” or “I” shape by drawing thematerial by MIM, PIM, milling, machining, or using a stamping and drawdie. In the “T”, ‘L” or “I” shape diffusers the center ring can be 0.005to 0.010 tall and the outer diameter is 0.090 and the inner diameter0.080, individually 0.001, 0.002, 0.003, 0.004, 0.005, 0.006, 0.007,0.008, 0.009, 0.010, 0.011, 0.012, 0.013, 0.014, 0.015, 0.02, 0.02.5,0.03, 0.04, 0.05,0.06, 0.07, 0.08, 0.09, 0.1, or 0.2.

FIGS. 5A-5H depict different embodiment of the diffuser of the presentinvention.

FIG. 6A depict a side, cross-sectional view of a two piece primer insertused in a polymeric cartridge case. The two piece primer insert (32)comprises: an upper primer insert portion (56) connected to a lowerprimer insert portion (58), wherein the upper primer insert portion (56)comprises an upper primer bottom surface (34), an upper primer aperture(33) through the upper primer bottom surface (34), and a substantiallycylindrical coupling element (30) extending away from the upper primerbottom surface (34), wherein the lower primer insert portion (58)comprises: a lower primer bottom surface (35) opposite a lower primertop surface (36), a primer recess (38) in the lower primer top surface(36) that extends toward the lower primer bottom surface (35) andadapted to fit a primer, a lower flash hole aperture (37) through thelower primer bottom surface (35), wherein the lower flash hole aperture(37) is larger than the upper primer aperture (33) to form a flash holegroove (39) in the primer recess (38)

FIGS. 6B-6D depict a side, cross-sectional view of a two piece primerinsert used in a polymeric cartridge case. The substantially cylindricalprimer insert 32 has an upper primer insert portion 56 and a lowerprimer insert portion 58 joined at insert joint 60. The upper primerinsert portion 56 may be of the same or different materials than lowerprimer insert portion 58. The upper primer insert portion 56 mates tothe lower primer insert portion 58 at insert joint 60 while retainingthe primer flash hole 40 and the primer recess 38. The insert joint 60may connect the upper primer insert portion 56 and the lower primerinsert portion 58 by welding or bonding using solvent, adhesive,spin-welding, vibration-welding, ultrasonic-welding or laser-weldingtechniques. In addition, multiple methods may be used to increase thejoint strength. The upper primer insert portion 56 includes asubstantially cylindrical coupling element 30 extending from a bottomsurface 34 that is opposite a top surface 36. The coupling element 30extends with a taper to a smaller diameter at the tip 44. Located in thetop surface 36 is a primer recess 38 that extends toward the bottomsurface 34. A primer flash hole 40 is located in the primer recess 38and extends through the bottom surface 34 into the propellant chamber14. The coupling end 22 of the middle body extends the polymer throughthe primer flash hole 40 to form an aperture coating (not shown) whileretaining a passage from the top surface 36 through the bottom surface34 and into the propellant chamber 14 to provide support and protectionabout the primer flash hole 40. When over-molded the coupling end 22interlocks with the substantially cylindrical coupling element 30. Thecoupling element 30 extends with a taper to a smaller diameter at thetip 44 to physical interlock the substantially cylindrical insert 32 tothe middle body component. The substantially cylindrical insert 32includes a substantially cylindrical coupling element 30 extending froma bottom surface 34 that is opposite a top surface 36. Located in thetop surface 36 is a primer recess 38 that extends toward the bottomsurface 34. A primer flash hole 40 is located in the primer recess 28and extends through the bottom surface 34 into the propellant chamber14. The coupling end 22 extends the polymer through the primer flashhole 40 to form an aperture coating (not shown) while retaining apassage from the top surface 36 through the bottom surface 34 and intothe propellant chamber 14 to provide support and protection about theprimer flash hole 40. When contacted the coupling end 22 interlocks withthe substantially cylindrical coupling element 30, through the couplingelement 30 that extends with a taper to a smaller diameter at the tip 44to physical interlock the substantially cylindrical insert 32 and themiddle body component 28.

The present invention provides a method of making a multi-piece insertthat is joined to form a unitary insert that can be overmolded into anammunition cartridge. The individual components of the insert may bemade may any method provided the insert is functional. For example, theindividual pieces may be stamped or milled and then connected. Theconnection can also be of any mechanism that is available currently thatproduces a viable insert with the desired joint strength. For example,the joint may be welded or soldered as in FIG. 7A or riveted or coinedas in FIG. 7B.

FIGS. 7A-7B depict a side, cross-sectional view of a two piece primerinsert used in a polymeric cartridge case. The substantially cylindricalprimer insert 32 has an upper primer insert portion 56 and a lowerprimer insert portion 58 joined at insert joint 60. The upper primerinsert portion 56 may be of the same or different materials than lowerprimer insert portion 58. The upper primer insert portion 56 mates tothe lower primer insert portion 58 at insert joint 60 while retainingthe primer flash hole 40 and the primer recess 38. The insert joint 60may connect the upper primer insert portion 56 and the lower primerinsert portion 58 by soldering, welding spin-welding, vibration-welding,ultrasonic-welding or laser-welding techniques as in FIG. 7A. FIG. 7Ashows a weld 68 joining the upper primer insert portion 56 and the lowerprimer insert portion 58. The weld 68 circumferentially surrounds theinsert joint 60. FIG. 7B shows both a riveted and a coined method ofjoining the upper primer insert portion 56 and the lower primer insertportion 58. The lower primer insert portion 58 has a rivet 70 thatextends through the upper primer insert portion 56 and secures the upperprimer insert portion 56 and the lower primer insert portion 58. FIG. 7Balso shows a coined method of joining the upper primer insert portion 56and the lower primer insert portion 58. The lower primer insert portion58 has a stud 72 that extends through the upper primer insert portion 56and is coined 74 to secure the upper primer insert portion 56 and thelower primer insert portion 58. In addition, multiple methods may beused to increase the joint strength. The upper primer insert portion 56includes a substantially cylindrical coupling element 30 extending froma bottom surface 34 that is opposite a top surface 36. The couplingelement 30 extends with a taper to a smaller diameter at the tip 44.Located in the top surface 36 is a primer recess 38 that extends towardthe bottom surface 34. A primer flash hole 40 is located in the primerrecess 38 and extends through the bottom surface 34 into the propellantchamber 14. The coupling end 22 of the middle body extends the polymerthrough the primer flash hole 40 to form an aperture coating (not shown)while retaining a passage from the top surface 36 through the bottomsurface 34 and into the propellant chamber 14 to provide support andprotection about the primer flash hole 40. When over-molded the couplingend 22 interlocks with the substantially cylindrical coupling element30. The coupling element 30 extends with a taper to a smaller diameterat the tip 44 to physical interlock the substantially cylindrical insert32 to the middle body component. The substantially cylindrical insert 32includes a substantially cylindrical coupling element 30 extending froma bottom surface 34 that is opposite a top surface 36. Located in thetop surface 36 is a primer recess 38 that extends toward the bottomsurface 34. A primer flash hole 40 is located in the primer recess 28and extends through the bottom surface 34 into the propellant chamber14. The coupling end 22 extends the polymer through the primer flashhole 40 to form an aperture coating (not shown) while retaining apassage from the top surface 36 through the bottom surface 34 and intothe propellant chamber 14 to provide support and protection about theprimer flash hole 40. When contacted the coupling end 22 interlocks withthe substantially cylindrical coupling element 30, through the couplingelement 30 that extends with a taper to a smaller diameter at the tip 44to physical interlock the substantially cylindrical insert 32 and themiddle body component 28.

FIGS. 8A-8C depict a side, cross-sectional view of a two piece primerinsert having a tab and groove configuration used in a polymericcartridge case. The substantially cylindrical primer insert 32 has anupper primer insert portion 56 and a lower primer insert portion 58joined at insert joint 60. The insert joint 60 has a tab 62 a and 62 bthat mate to the corresponding groove 64 a and 64 b to further securethe upper primer insert portion 56 and a lower primer insert portion 58.The location, shape and position of the tab 62 a/62 b and groove 64 a/64b may be varied by the skilled artisan as necessary to secure the upperprimer insert portion 56 and a lower primer insert portion 58. The upperprimer insert portion 56 may be of the same or different materials thanlower primer insert portion 58. The upper primer insert portion 56 matesto the lower primer insert portion 58 at insert joint 60 while retainingthe primer flash hole 40 and the primer recess 38. The insert joint 60may connect the upper primer insert portion 56 and the lower primerinsert portion 58 by welding or bonding using solvent, adhesive,spin-welding, vibration-welding, ultrasonic-welding or laser-weldingtechniques. In addition, multiple methods may be used to increase thejoint strength. The upper primer insert portion 56 includes asubstantially cylindrical coupling element 30 extending from a bottomsurface 34 that is opposite a top surface 36. The coupling element 30extends with a taper to a smaller diameter at the tip 44. Located in thetop surface 36 is a primer recess 38 that extends toward the bottomsurface 34. A primer flash hole 40 is located in the primer recess 38and extends through the bottom surface 34 into the propellant chamber14. The coupling end 22 of the middle body extends the polymer throughthe primer flash hole 40 to form an aperture coating (not shown) whileretaining a passage from the top surface 36 through the bottom surface34 and into the propellant chamber 14 to provide support and protectionabout the primer flash hole 40. When over-molded the coupling end 22interlocks with the substantially cylindrical coupling element 30. Thecoupling element 30 extends with a taper to a smaller diameter at thetip 44 to physical interlock the substantially cylindrical insert 32 tothe middle body component. The substantially cylindrical insert 32includes a substantially cylindrical coupling element 30 extending froma bottom surface 34 that is opposite a top surface 36. Located in thetop surface 36 is a primer recess 38 that extends toward the bottomsurface 34. A primer flash hole 40 is located in the primer recess 28and extends through the bottom surface 34 into the propellant chamber14. The coupling end 22 extends the polymer through the primer flashhole 40 to form an aperture coating (not shown) while retaining apassage from the top surface 36 through the bottom surface 34 and intothe propellant chamber 14 to provide support and protection about theprimer flash hole 40. When contacted the coupling end 22 interlocks withthe substantially cylindrical coupling element 30, through the couplingelement 30 that extends with a taper to a smaller diameter at the tip 44to physical interlock the substantially cylindrical insert 32 and themiddle body component 28.

Multiple piece inserts of the present invention may be configured invarious ways. For example, the insert may be include three insertpieces, three insert pieces configured without the need for a diffuser,three insert pieces where one piece is a diffuser, three insert pieceswhere the diffuser is between the other insert pieces.

FIG. 9A depicts a side, cross-sectional view of a three piece primerinsert having a tab and groove configuration used in a polymericcartridge case. The substantially cylindrical primer insert 32 has anupper primer insert portion 56, a middle insert 76 and a lower primerinsert portion 58 joined at the insert joints 60 a and 60 b. The middleinsert 76 has tabs 62 a and 62 b that mate to the corresponding groove64 a and 64 b to further secure the upper primer insert portion 56 andthe middle insert 76. The middle insert 76 also has tabs 62 c and 62 dthat mate to the corresponding groove 64 c and 64 d to further securethe lower primer insert portion 58 and the middle insert 76. Thiscreates insert joint 60 a between the upper primer insert portion 56 andthe middle insert 76 and insert joint 60 b between the lower primerinsert portion 58 and the middle insert 76. The middle insert 76 has aflash hole aperture 78 that connects the upper primer insert portion 56and the lower primer insert portion 58. In some instances the flash holeaperture 78 may have a diameter less than the diameter of the primerflash hole 40. The location, shape and position of the tab 62 a-62 d andgroove 64 a-64 d may be varied by the skilled artisan as necessary tosecure the upper primer insert portion 56, the middle insert 76 and thelower primer insert portion 58. The upper primer insert portion 56 maybe of the same or different materials than lower primer insert portion58. The upper primer insert portion 56 mates to the lower primer insertportion 58 at insert joint 60 while retaining the primer flash hole 40and the primer recess 38. The insert joint 60 may connect the upperprimer insert portion 56 and the lower primer insert portion 58 bywelding or bonding using solvent, adhesive, spin-welding,vibration-welding, ultrasonic-welding or laser-welding techniques. Inaddition, multiple methods may be used to increase the joint strength.The upper primer insert portion 56 includes a substantially cylindricalcoupling element 30 extending from a bottom surface 34 that is oppositea top surface 36. The coupling element 30 extends with a taper to asmaller diameter at the tip 44. Located in the top surface 36 is aprimer recess 38 that extends toward the bottom surface 34. A primerflash hole 40 is located in the primer recess 38 and extends through thebottom surface 34 into the propellant chamber (not shown). The couplingend 22 of the middle body extends the polymer through the primer flashhole 40 to form an aperture coating (not shown) while retaining apassage from the top surface 36 through the bottom surface 34 and intothe propellant chamber (not shown) to provide support and protectionabout the primer flash hole 40. When over-molded the coupling end 22interlocks with the substantially cylindrical coupling element 30. Thecoupling element 30 extends with a taper to a smaller diameter at thetip 44 to physical interlock the substantially cylindrical insert 32 tothe middle body component. The substantially cylindrical insert 32includes a substantially cylindrical coupling element 30 extending froma bottom surface 34 that is opposite a top surface 36. Located in thetop surface 36 is a primer recess 38 that extends toward the bottomsurface 34. A primer flash hole 40 is located in the primer recess 28and extends through the bottom surface 34 into the propellant chamber(not shown). The coupling end 22 extends the polymer through the primerflash hole 40 to form an aperture coating (not shown) while retaining apassage from the top surface 36 through the bottom surface 34 and intothe propellant chamber 14 to provide support and protection about theprimer flash hole 40. When contacted the coupling end 22 interlocks withthe substantially cylindrical coupling element 30, through the couplingelement 30 that extends with a taper to a smaller diameter at the tip 44to physical interlock the substantially cylindrical insert 32 and themiddle body component 28.

FIG. 9B depicts a side, cross-sectional view of a three piece primerinsert having a tab and groove or a simple alignment configuration usedin a polymeric cartridge case. The substantially cylindrical primerinsert 32 has an upper primer insert portion 56, a middle insert 76 anda lower primer insert portion 58 joined at the insert joints 60 a and 60b. The middle insert 76 has a tab aperture 80 that receives the tab 62that mate to the corresponding groove 64 to further secure the upperprimer insert portion 56, the middle insert 76 and the lower primerinsert portion 58. Alternatively, the middle insert 76 may be a relativeflat insert that aligns with the upper primer insert portion 56 and thelower primer insert portion 58. This creates insert joint 60 a betweenthe upper primer insert portion 56 and the middle insert 76 and insertjoint 60 b between the lower primer insert portion 58 and the middleinsert 76. The middle insert 76 has a flash hole aperture 78 thatconnects the upper primer insert portion 56 and the lower primer insertportion 58. In some instances, the flash hole aperture 78 may have adiameter less than the diameter of the primer flash hole 40. Thelocation, shape and position of the tab 62 and groove 64 may be variedby the skilled artisan as necessary to secure the upper primer insertportion 56, the middle insert 76 and the lower primer insert portion 58.The upper primer insert portion 56, the middle insert 76 and the lowerprimer insert portion 58 may individually be of the same or differentmaterials. The upper primer insert portion 56 mates to the middle insert76 at insert joint 60 a and to the lower primer insert portion 58 atinsert joint 60 b while retaining the primer flash hole 40 and theprimer recess 38. The inserts joint 60 a and 60 b may connect the upperprimer insert portion 56, the middle insert 76 and the lower primerinsert portion 58 by threading, riveting, locking, friction fitting,coining, snap fitting, chemical bonding, chemical welding, soldering,smelting, sintering, adhesive bonding, laser welding, ultrasonicwelding, friction spot welding, friction stir welding spin-welding,vibration-welding, ultrasonic-welding or laser-welding techniques. Inaddition, multiple methods may be used to increase the joint strength.

The upper primer insert portion 56 includes a substantially cylindricalcoupling element 30 extending from a bottom surface 34 that is oppositea top surface 36. The coupling element 30 extends with a taper to asmaller diameter at the tip 44. Located in the top surface 36 is aprimer recess 38 that extends toward the bottom surface 34. A primerflash hole 40 is located in the primer recess 38 and extends through thebottom surface 34 into the propellant chamber (not shown). The couplingend 22 of the middle body extends the polymer through the primer flashhole 40 to form an aperture coating (not shown) while retaining apassage from the top surface 36 through the bottom surface 34 and intothe propellant chamber 14 to provide support and protection about theprimer flash hole 40. When over-molded the coupling end 22 interlockswith the substantially cylindrical coupling element 30. The couplingelement 30 extends with a taper to a smaller diameter at the tip 44 tophysical interlock the substantially cylindrical insert 32 to the middlebody component. The substantially cylindrical insert 32 includes asubstantially cylindrical coupling element 30 extending from a bottomsurface 34 that is opposite a top surface 36. Located in the top surface36 is a primer recess 38 that extends toward the bottom surface 34. Aprimer flash hole 40 is located in the primer recess 28 and extendsthrough the bottom surface 34 into the propellant chamber 14. Thecoupling end 22 extends the polymer through the primer flash hole 40 toform an aperture coating (not shown) while retaining a passage from thetop surface 36 through the bottom surface 34 and into the propellantchamber 14 to provide support and protection about the primer flash hole40. When contacted the coupling end 22 interlocks with the substantiallycylindrical coupling element 30, through the coupling element 30 thatextends with a taper to a smaller diameter at the tip 44 to physicalinterlock the substantially cylindrical insert 32 and the middle bodycomponent 28.

FIG. 10 depicts a perspective view of a two piece primer insert used ina polymeric cartridge case. The substantially cylindrical primer insert32 has an upper primer insert portion 56 and a lower primer insertportion 58 joined at insert joint 60. The upper primer insert portion 56may be of the same or different materials than lower primer insertportion 58. The upper primer insert portion 56 mates to the lower primerinsert portion 58 at insert joint 60 while retaining the primer flashhole 40 and the primer recess (not shown). The insert joint 60 mayconnect the upper primer insert portion 56 and the lower primer insertportion 58 by welding or bonding using solvent, adhesive, spin-welding,vibration-welding, ultrasonic-welding or laser-welding techniques. Inaddition, multiple methods may be used to increase the joint strength.The upper primer insert portion 56 includes a substantially cylindricalcoupling element 30 extending from a bottom surface (not shown) that isopposite a top surface (not shown). The coupling element 30 extends witha taper to a smaller diameter at the tip 44. Located in the top surface(not shown) is a primer recess (not shown) that extends toward thebottom surface (not shown). A primer flash hole (not shown) is locatedin the primer recess (not shown) and extends through the bottom surface(not shown) into the propellant chamber (not shown). The lower primerinsert portion 58 includes a flange 46 that may have a smooth transitionaround the surface or may have various designs positioned around thesurface. The design, shape and number of notches 66 will depend on thespecific application and desire of the manufacturer but may include 1,2, 3, 4, 5 6, 7, 8, 9, 10, or more notches.

Chemical welding and chemical bonding involves the use of chemicalcompositions that undergoes a chemical or physical reaction resulting inthe joining of the materials and the formation of a unitary primerinsert. The chemicals may join the surfaces through the formation of alayer that contacts both surfaces or by melting the surfaces to a singleinterface between the surfaces.

Adhesive bonding involves the use of a polymeric adhesive, whichundergoes a chemical or physical reaction, for eventual joint formation.The upper primer insert portion mates to the lower primer insert portionat the insert joint to which an adhesive material has been added to forma unitary primer insert. The adhesive includes high-strength and toughadhesives that can withstand both static and alternating loads.

Sintering involves the process of compacting and forming a solid mass ofmaterial by heat and/or pressure without melting it to the point ofliquefaction. Materials that are identical or similar may be sintered inthe temperature range for the specific time, e.g., stainless steel maybe heated for 30-60 minutes at a temperature of between 2000-2350° F.However, materials that are dissimilar may be heated at the within thecommon temperature range (±400° F.) for the specific time (±0.5-2hours). For example, the upper primer insert portion may be stainlesssteel with a temperature range form 2000-2350° F. for 30-60 minutes andthe lower primer insert portion may be nickel 1850-2100° F. for 30-45minutes (and vice versa) to allow the sintering at between 2000-2100° F.for 30-60 minutes. Similarly, the upper primer insert portion may bestainless steel with a temperature range form 2000-2350° F. for 30-60minutes and the lower primer insert portion may be tungsten carbide2600-2700° F. for 20-30 minutes to allow the sintering at between2300-2600° F. for 30-60 minutes or longer if necessary. The skilledartisan readily understands the parameters associated with sinteringmaterials of similar and different compositions and therefor there is noneed in reciting all of the various combinations that can be formed inthis application.

Welding techniques including laser welding, ultrasonic welding, frictionspot welding, and friction stir welding. The welding methods can use theexisting materials to fill in the insert joint or an additional materialmay be used to fill in the insert joint. The dissimilar multi-metalwelded unitary primer insert must be examined to determine the cracksensitivity, ductility, susceptibility to corrosion, etc. In some cases,it is necessary to use a third metal that is soluble with each metal inorder to produce a successful joint.

The two piece primer insert used in polymeric cartridge cases includesan upper primer insert portion and a lower primer insert portion joinedat insert joint. The individual upper primer insert portion and lowerprimer insert portion may be formed in various methods. For example theindividual upper primer insert portion and lower primer insert portionmay be formed by metal injection molding, polymer injection molding,stamping, milling, molding, machining, punching, fine blanking,smelting, or any other method that will form insert portions that may bejoined together to form a primer insert.

The two piece primer insert includes an individual upper primer insertportion and lower primer insert portion formed in various methods. Forexample, the individual upper primer insert portion and lower primerinsert portion may be formed by stamping, milling, or machining and thenjoined together to form a primer insert.

For example, the individual upper primer insert portion, the lowerprimer insert portion or both may be formed by fineblanking.Fineblanking is a specialty type of metal stamping that can achieve partcharacteristics such as flatness and a full sheared edge to a degreethat is nearly impossible using a conventional metal cutting or punchingprocess and is used to achieve flatness and cut edge characteristicsthat are unobtainable by conventional stamping and punching methods.When the punch makes contact with the sheet, the metal begins to deformand bulge around the point of the punch. As the yield strength of thepart material is exceeded by the downward force of the press, the pointof the punch begins to penetrate the metal's surface. Both the punch andmatrix, or button, begin to cut from their respective sides. When theultimate tensile strength has been reached, the metal breaks orfractures from the edge of the punch to the edge of the matrix. Thisresults in a cut edge that appears to be partially cut and partiallybroken or fractured. This cut edge condition often is referred to as the“cut band.” In most cases, the cut edge has about 10 percent to 30percent of shear, and the remainder is fractured. The fracture has twoprimary causes. The distance between the punch and the matrix creates aleverage action and tends to pull the metal apart, causing it torupture. The deformation that is allowed during the cutting process alsoallows the metal to fracture prematurely. Allowing the metal to deformseverely during the cutting process results in straining of the metal,which in turn causes a stress. Trapped stresses in a product cause it tolose its flatness, which is why it is very difficult to maintain acritical flatness characteristic using conventional methods.Fineblanking requires the use of three very high-pressure pads in aspecial press. These pads hold the metal flat during the cutting processand keep the metal from plastically deforming during punch entry. Mostfineblanking operations incorporate a V-ring into one of thehigh-pressure pads. This ring also is commonly referred to as a“stinger” or “impingement” ring. Before the punch contacts the part, thering impales the metal, surrounds the perimeter of the part, and trapsthe metal from moving outward while pushing it inward toward the punch.This reduces rollover at the cut edge. Fineblanking operations usuallyrequire clearances of less than 0.0005 inch per side. This smallclearance, combined with high pressure, results in a fully sheared partedge. Fineblanking is much like a cold extruding process. The slug (orpart) is pushed or extruded out of the strip while it is held verytightly between the high-pressure holding plates and pads. The tighthold of the high-pressure plates prevents the metal from bulging orplastically deforming during the extrusion process.

The two piece primer insert includes an individual upper primer insertportion and lower primer insert portion formed in various methods. Forexample, the individual upper primer insert portion and lower primerinsert portion may be formed by molding, injection molding or metalinjection molding and then joined together to form a primer insert.

For example, when the individual upper primer insert portion and lowerprimer insert portion or both are metal injection molded, the rawmaterials are metal powders and a thermoplastic binder. There are atleast two Binders included in the blend, a primary binder and asecondary binder. This blended powder mix is worked into the plasticizedbinder at elevated temperature in a kneader or shear roll extruder. Theintermediate product is the so-called feedstock. It is usuallygranulated with granule sizes of several millimeters. In metal injectionmolding, only the binders are heated up, and that is how the metal iscarried into the mold cavity.

In preparing a feedstock, it is important first to measure the actualdensity of each lot of both the metal powders and binders. This isextremely important especially for the metal powders in that each lotwill be different based on the actual chemistry of that grade of powder.For example, 316L is comprised of several elements, such as Fe, Cr, Ni,Cu, Mo, P, Si, S and C. In order to be rightfully called a 316L, each ofthese elements must meet a minimum and maximum percentage weightrequirement as called out in the relevant specification. Tables I-IVbelow provide other examples of the elemental compositions of some ofthe metal powders, feed stocks, metals, alloys and compositions of thepresent invention. Hence the variation in the chemistry within thespecification results in a significant density variation within theacceptable composition range. Depending on the lot received from thepowder producer, the density will vary depending on the actual chemistryreceived.

TABLE I Material Chemical Composition, % - Low-Alloy Steels DesignationCode Fe Ni Mo C Si (max) MIM-2200⁽¹⁾ Bal. 1.5-2.5 0.5 max 0.1 max 1.0MIM-2700 Bal. 6.5-8.5 0.5 max 0.1 max 1.0 MIM-4605⁽²⁾ Bal. 1.5-2.50.2-0.5 0.4-0.6 1.0

TABLE II Material Chemical Composition, % - Stainless Steels DesignationCode Fe Ni Cr Mo C Cu Nb + Ta Mn (max) Si (max) MIM-316L Bal. 10-1416-18 2-3 0.03 max — — 2.0 1.0 MIM-420 Bal. — 12-14 — 0.15-0.4 — — 1.01.0 MIM-430L Bal. — 16-18 — 0.05 max — — 1.0 1.0 MIM-17-4 PH Bal. 3-515.5-17.5 — 0.07 max 3-5 0.15-0.45 1.0 1.0

TABLE III Material Chemical Composition, % - Soft-Magnetic AlloysDesignation Code Fe Ni Cr Co Si C (max) Mn V MIM-2200 Bal. 1.5-2.5 — —1.0 max 0.1 — — MIM-Fe—3%Si Bal. — — — 2.5-3.5 0.05 — — MIM-Fe50%Ni Bal.49-51 — — 1.0 max 0.05 — — MIM-Fe50%Co Bal. — — 48-50 1.0 max 0.05 — 2.5max MIM-430L Bal. — 16-18 — 1.0 max 0.05 1.0 max —

TABLE IV Nominal Chemical Composition, % - Controlled-Expansion AlloysMaterial Mn Si C Al Mg Zr Ti Cu Cr Mo Designation Fe Ni Co max max maxmax max max max max max max MIM-F15 Bal. 29 17 0.50 0.20 0.04 0.10 0.100.10 0.10 0.20 0.20 0.20

In addition to the specific compositions listed herein, the skillartisan recognizes the elemental composition of common commercialdesignations used by feedstock manufacturers and processors, e.g.,C-0000 Copper and Copper Alloys; CFTG-3806-K Diluted Bronze Bearings;CNZ-1818 Copper and Copper Alloys; CNZP-1816 Copper and Copper Alloys;CT-1000 Copper and Copper Alloys; CT-1000-K Bronze Bearings; CTG-1001-KBronze Bearings; CTG-1004-K Bronze Bearings; CZ-1000 Copper and CopperAlloys; CZ-2000 Copper and Copper Alloys; CZ-3000 Copper and CopperAlloys; CZP-1002 Copper and Copper Alloys; CZP-2002 Copper and CopperAlloys; CZP-3002 Copper and Copper Alloys; F-0000 Iron and Carbon Steel;F-0000-K Iron and Iron-Carbon Bearings; F-0005 Iron and Carbon Steel;F-0005-K Iron and Iron-Carbon Bearings; F-0008 Iron and Carbon Steel;F-0008-K Iron and Iron-Carbon Bearings; FC-0200 Iron-Copper and CopperSteel; FC-0200-K Iron-Copper Bearings; FC-0205 Iron-Copper and CopperSteel; FC-0205-K Iron-Copper-Carbon Bearings; FC-0208 Iron-Copper andCopper Steel; FC-0208-K Iron-Copper-Carbon Bearings; FC-0505 Iron-Copperand Copper Steel; FC-0508 Iron-Copper and Copper Steel; FC-0508-KIron-Copper-Carbon Bearings; FC-0808 Iron-Copper and Copper Steel;FC-1000 Iron-Copper and Copper Steel; FC-1000-K Iron-Copper Bearings;FC-2000-K Iron-Copper Bearings; FC-2008-K Iron-Copper-Carbon Bearings;FCTG-3604-K Diluted Bronze Bearings; FD-0200 Diffusion-Alloyed Steel;FD-0205 Diffusion-Alloyed Steel; FD-0208 Diffusion-Alloyed Steel;FD-0400 Diffusion-Alloyed Steel; FD-0405 Diffusion-Alloyed Steel;FD-0408 Diffusion-Alloyed Steel; FF-0000 Soft-Magnetic Alloys; FG-0303-KIron-Graphite Bearings; FG-0308-K Iron-Graphite Bearings; FL-4005Prealloyed Steel; FL-4205 Prealloyed Steel; FL-4400 Prealloyed Steel;FL-4405 Prealloyed Steel; FL-4605 Prealloyed Steel; FL-4805 PrealloyedSteel; FL-48105 Prealloyed Steel; FL-4905 Prealloyed Steel; FL-5208Prealloyed Steel; FL-5305 Prealloyed Steel; FLC-4608 Sinter-HardenedSteel; FLC-4805 Sinter-Hardened Steel; FLC-48108 Sinter-Hardened Steel;FLC-4908 Sinter-Hardened Steel; FLC2-4808 Sinter-Hardened Steel;FLDN2-4908 Diffusion-Alloyed Steel; FLDN4C2-4905 Diffusion-AlloyedSteel; FLN-4205 Hybrid Low-Alloy Steel; FLN-48108 Sinter-Hardened Steel;FLN2-4400 Hybrid Low-Alloy Steel; FLN2-4405 Hybrid Low-Alloy Steel;FLN2-4408 Sinter-Hardened Steel; FLN2C-4005 Hybrid Low-Alloy Steel;FLN4-4400 Hybrid Low-Alloy Steel; FLN4-4405 Hybrid Low-Alloy Steel;FLN4-4408 Sinter Hardened Steel; FLN4C-4005 Hybrid Low-Alloy Steel;FLN6-4405 Hybrid Low-Alloy Steel; FLN6-4408 Sinter-Hardened Steel;FLNC-4405 Hybrid Low-Alloy Steel; FLNC-4408 Sinter-Hardened Steel;FN-0200 Iron-Nickel and Nickel Steel; FN-0205 Iron-Nickel and NickelSteel; FN-0208 Iron-Nickel and Nickel Steel; FN-0405 Iron-Nickel andNickel Steel; FN-0408 Iron-Nickel and Nickel Steel; FN-5000Soft-Magnetic Alloys; FS-0300 Soft-Magnetic Alloys; FX-1000Copper-Infiltrated Iron and Steel; FX-1005 Copper-Infiltrated Iron andSteel; FX-1008 Copper-Infiltrated Iron and Steel; FX-2000Copper-Infiltrated Iron and Steel; FX-2005 Copper-Infiltrated Iron andSteel; FX-2008 Copper-Infiltrated Iron and Steel; FY-4500 Soft-MagneticAlloys; FY-8000 Soft-Magnetic Alloys; P/F-1020 Carbon Steel PF; P/F-1040Carbon Steel PF; P/F-1060 Carbon Steel PF; P/F-10C40 Copper Steel PF;P/F-10C50 Copper Steel PF; P/F-10C60 Copper Steel PF; P/F-1140 CarbonSteel PF; P/F-1160 Carbon Steel PF; P/F-11C40 Copper Steel PF;P/F-11C50Copper Steel PF; P/F-11C60 Copper Steel PF; P/F-4220 Low-Alloy P/F-42XXSteel PF; P/F-4240 Low-Alloy P/F-42XX Steel PF; P/F-4260 Low-AlloyP/F-42XX Steel PF; P/F-4620 Low-Alloy P/F-46XX Steel PF; P/F-4640Low-Alloy P/F-46XX Steel PF; P/F-4660 Low-Alloy P/F-46XX Steel PF;P/F-4680 Low-Alloy P/F-46XX Steel PF; SS-303L Stainless Steel—300 SeriesAlloy; SS-303N1 Stainless Steel—300 Series Alloy; SS-303N2 StainlessSteel—300 Series Alloy; SS-304H Stainless Steel—300 Series Alloy;SS-304L Stainless Steel—300 Series Alloy; SS-304N1 Stainless Steel—300Series Alloy; SS-304N2 Stainless Steel—300 Series Alloy; SS-316HStainless Steel—300 Series Alloy; SS-316L Stainless Steel—300 SeriesAlloy; SS-316N1 Stainless Steel—300 Series Alloy; SS-316N2 StainlessSteel—300 Series Alloy; SS-409L Stainless Steel—400 Series Alloy;SS-409LE Stainless Steel—400 Series Alloy; SS-410 Stainless Steel—400Series Alloy; SS-410L Stainless Steel—400 Series Alloy; SS-430LStainless Steel—400 Series Alloy; SS-430N2 Stainless Steel—400 SeriesAlloy; SS-434L Stainless Steel—400 Series Alloy; SS-434LCb StainlessSteel—400 Series Alloy; and SS-434N2 Stainless Steel—400 Series Alloy.

Parts are molded until they feel that the cavity has been filled. Bothmold design factors such as runner and gate size, gate placement,venting and molding parameters set on the molding machine affect themolded part. A helium Pycnometer can determine if there are voidstrapped inside the parts. During molding, you have a tool that can beused to measure the percent of theoretical density achieved on the“Green” or molded part. By crushing the measured “green” molded partback to powder, you can now confirm the percent of air (or voids)trapped in the molded part. To measure this, the density of the moldedpart should be measured in the helium Pycnometer and compared to thetheoretical density of the feedstock. Then, take the same molded partthat was used in the density test and crush it back to powder. If thisgranulate shows a density of more than 100% of that of the feedstock,then some of the primary binders have been lost during the moldingprocess. The molding process needs to be corrected because using thisprocess with a degraded feedstock will result in a larger shrinkage andresult in a part smaller than that desired. It is vital to be sure thatyour molded parts are completely filled before continuing themanufacturing process for debinding and sintering. The helium Pycnometerprovides this assurance. Primary debinding properly debound parts areextremely important to establish the correct sintering profile. Theprimary binder must be completely removed before attempting to start toremove the secondary binder as the secondary binder will travel throughthe pores created by the extraction of the primary binder. Primarydebinding techniques depend on the feedstock type used to make theparts. However the feedstock supplier knows the amount of primarybinders that have been added and should be removed before proceeding tothe next process step. The feedstock supplier provides a minimum “browndensity” that must be achieved before the parts can be moved into afurnace for final debinding and sintering. This minimum brown densitywill take into account that a small amount of the primary binder remnantmay be present and could be removed by a suitable hold during secondarydebinding and sintering. The sintering profile should be adjusted toremove the remaining small percent of primary binder before the removalof the secondary binder. Most external feedstock manufacturers provideonly a weight loss percent that should be obtained to define suitabledebinding. Solvent debound parts must be thoroughly dried, before thehelium Pycnometer is used to determine the “brown” density so that theremnant solvent in the part does not affect the measured density value.When the feedstock manufacturer gives you the theoretical density of the“brown” or debound part, can validate the percent of debinding that hasbeen achieved. Most Metal Injection Molding (MIM) operations todayperform the secondary debinding and sintering in the same operation.Every MIM molder has gates and runners left over from molding theirparts. So, you will be able to now re-use your gates and runners withconfidence that they will shrink correctly after sintering. If thefeedstock producers have given you the actual and theoretical densitiesof their feedstock, you can easily measure the densities of the gatesand runners and compare the results to the values supplied. Once theregrind densities are higher than that required to maintain the partdimensions, the regrinds are no longer reusable.

Feedstock in accordance with the present invention may be prepared byblending the powdered metal with the binder and heating the blend toform a slurry. Uniform dispersion of the powdered metal in the slurrymay be achieved by employing high shear mixing. The slurry may then becooled to ambient temperature and then granulated to provide thefeedstock for the metal injection molding.

One embodiment of the injection molded primer insert may include acomposition where Ni may be 2.0, 2.25, 2.50, 2.75, 3.0, 3.25, 3.5, 3.75,4.0, 4.25, 4.50, 4.75, 5.0, 5.25, 5.5, 5.75, 6.0, 6.25, 6.50, 6.75, 7.0,7.25, 7.5, 7.75, 8.0, 8.25, 8.50, 8.75, 9.0, 9.25, 9.5, 9.75, 10.0,10.25, 10.50, 10.75, 11.0, 11.25, 11.5, 11.75, 12.0, 12.25, 12.50,12.75, 13.0, 13.25, 13.5, 13.75, 14.0, 14.25, 14.50, 14.75, 15.0, 15.25,15.5, 15.75, 16.0, 16.25, 16.50, 16.75, or 17.0%; Cr may be 9.0, 9.25,9.5, 9.75, 10.0, 10.25, 10.50, 10.75, 11.0, 11.25, 11.5, 11.75, 12.0,12.25, 12.50, 12.75, 13.0, 13.25, 13.5, 13.75, 14.0, 14.25, 14.50,14.75, 15.0, 15.25, 15.5, 15.75, 16.0, 16.25, 16.50, 16.75, 17.0, 17.25,17.5, 17.75, 18.0, 18.25, 18.50, 18.75, 19.0, 19.25, 19.5, 19.75, or20.0%; Mo may be 0.00, 0.025, 0.050, 0.075, 0.10, 0.125, 0.150, 0.175,0.20, 0.225, 0.250, 0.275, 0.30, 0.325, 0.350, 0.375, 0.40, 0.425,0.450, 0.475, 0.50, 0.525, 0.550, 0.575, 0.60, 0.625, 0.650, 0.675,0.70, 0.725, 0.750, 0.775, 0.80, 0.825, 0.850, 0.875, 0.90, 0.925,0.950, 1.0, 1.25, 1.5, 1.75, 2.0, 2.25, 2.50, 2.75, 3.0, 3.25, 3.5,3.75, 4.0, 4.25, 4.50, 4.75, 5.0, 5.25, 5.5, 5.75, 6.0, 6.25, 6.50,6.75, or 7.0%; C may be 0.00, 0.025, 0.050, 0.075, 0.10, 0.125, 0.150,0.175, 0.20, 0.225, 0.250, 0.275, 0.30, 0.325, 0.350, 0.375, 0.40,0.425, 0.450, 0.475, 0.50, 0.525, 0.550, 0.575, 0.60, 0.625, 0.650,0.675, 0.70, 0.725, 0.750, 0.775, 0.80, 0.825, 0.850, 0.875, 0.90,0.925, 0.950, or 1.00%; Cu may be 0.00, 0.025, 0.050, 0.075, 0.10,0.125, 0.150, 0.175, 0.20, 0.225, 0.250, 0.275, 0.30, 0.325, 0.350,0.375, 0.40, 0.425, 0.450, 0.475, 0.50, 0.525, 0.550, 0.575, 0.60,0.625, 0.650, 0.675, 0.70, 0.725, 0.750, 0.775, 0.80, 0.825, 0.850,0.875, 0.90, 0.925, 0.950, 1.0, 1.25, 1.5, 1.75, 2.0, 2.25, 2.50, 2.75,3.0, 3.25, 3.5, 3.75, 4.0, 4.25, 4.50, 4.75, 5.0, 5.25, 5.5, 5.75, 6.0,6.25, 6.50, 6.75, 7.0, 7.25, 7.5, 7.75, or 8.0%; Nb+Ta may be 0.00,0.025, 0.050, 0.075, 0.10, 0.125, 0.150, 0.175, 0.20, 0.225, 0.250,0.275, 0.30, 0.325, 0.350, 0.375, 0.40, 0.425, 0.450, 0.475, 0.50,0.525, 0.550, 0.575, 0.60, 0.625, 0.650, 0.675, 0.70, 0.725, 0.750,0.775, or 0.80%; Mn may be 0.00, 0.025, 0.050, 0.075, 0.10, 0.125,0.150, 0.175, 0.20, 0.225, 0.250, 0.275, 0.30, 0.325, 0.350, 0.375,0.40, 0.425, 0.450, 0.475, 0.50, 0.525, 0.550, 0.575, 0.60, 0.625,0.650, 0.675, 0.70, 0.725, 0.750, 0.775, 0.80, 0.825, 0.850, 0.875,0.90, 0.925, 0.950, 1.0, 1.25, 1.5, 1.75, 2.0, 2.25, 2.50, 2.75, 3.0,3.25, 3.5, 3.75, 4.0, 4.25, 4.50, 4.75, 5.0, 5.25, 5.5, 5.75, or 6.0%;Si may be 0.00, 0.025, 0.050, 0.075, 0.10, 0.125, 0.150, 0.175, 0.20,0.225, 0.250, 0.275, 0.30, 0.325, 0.350, 0.375, 0.40, 0.425, 0.450,0.475, 0.50, 0.525, 0.550, 0.575, 0.60, 0.625, 0.650, 0.675, 0.70,0.725, 0.750, 0.775, 0.80, 0.825, 0.850, 0.875, 0.90, 0.925, 0.950, 1.0,1.25, 1.5, 1.75, 2.0, 2.25, 2.50, 2.75, 3.0, 3.25, 3.5, 3.75, or 4.0%;and the balance Fe.

For example, one embodiment of the injection molded primer insert mayinclude any amount in the range of 2-16% Ni; 10-20% Cr; 0-5% Mo; 0-0.6%C; 0-6.0% Cu; 0-0.5% Nb+Ta; 0-4.0% Mn; 0-2.0% Si and the balance Fe. Oneembodiment of the injection molded primer insert may include any amountin the range of 2-6% Ni; 13.5-19.5% Cr; 0-0.10% C; 1-7.0% Cu; 0.05-0.65%Nb+Ta; 0-3.0% Mn; 0-3.0% Si and the balance Fe. One embodiment of theinjection molded primer insert may include any amount in the range of3-5% Ni; 15.5-17.5% Cr; 0-0.07% C; 3-5.0% Cu; 0.15-0.45% Nb+Ta; 0-1.0%Mn; 0-1.0% Si and the balance Fe. One embodiment of the injection moldedprimer insert may include any amount in the range of 10-14% Ni; 16-18%Cr; 2-3% Mo; 0-0.03% C; 0-2% Mn; 0-1% Si and the balance Fe. Oneembodiment of the injection molded primer insert may include any amountin the range of 12-14% Cr; 0.15-0.4% C; 0-1% Mn; 0-1% Si and the balanceFe. One embodiment of the injection molded primer insert may include anyamount in the range of 16-18% Cr; 0-0.05% C; 0-1% Mn; 0-1% Si and thebalance Fe.

Titanium alloys that may be used in this invention include any alloy ormodified alloy known to the skilled artisan including titanium grades5-38 and more specifically titanium grades 5, 9, 18, 19, 20, 21, 23, 24,25, 28, 29, 35, 36 or 38. Grades 5, 23, 24, 25, 29, 35, or 36 annealedor aged; Grades 9, 18, 28, or 38 cold-worked and stress-relieved orannealed; Grades 9, 18, 23, 28, or 29 transformed-beta condition; andGrades 19, 20, or 21 solution-treated or solution-treated and aged.Grade 5, also known as Ti6Al4V, Ti-6Al-4V or Ti 6-4, is the mostcommonly used alloy. It has a chemical composition of 6% aluminum, 4%vanadium, 0.25% (maximum) iron, 0.2% (maximum) oxygen, and the remaindertitanium. It is significantly stronger than commercially pure titaniumwhile having the same stiffness and thermal properties (excludingthermal conductivity, which is about 60% lower in Grade 5 Ti than in CPTi); Grade 6 contains 5% aluminum and 2.5% tin. It is also known asTi-5Al-2.5Sn. This alloy has good weldability, stability and strength atelevated temperatures; Grade 7 and 7H contains 0.12 to 0.25% palladium.This grade is similar to Grade 2. The small quantity of palladium addedgives it enhanced crevice corrosion resistance at low temperatures andhigh pH; Grade 9 contains 3.0% aluminum and 2.5% vanadium. This grade isa compromise between the ease of welding and manufacturing of the “pure”grades and the high strength of Grade 5; Grade 11 contains 0.12 to 0.25%palladium; Grade 12 contains 0.3% molybdenum and 0.8% nickel; Grades 13,14, and 15 all contain 0.5% nickel and 0.05% ruthenium; Grade 16contains 0.04 to 0.08% palladium; Grade 16H contains 0.04 to 0.08%palladium; Grade 17 contains 0.04 to 0.08% palladium; Grade 18 contains3% aluminum, 2.5% vanadium and 0.04 to 0.08% palladium; Grade 19contains 3% aluminum, 8% vanadium, 6% chromium, 4% zirconium, and 4%molybdenum; Grade 20 contains 3% aluminum, 8% vanadium, 6% chromium, 4%zirconium, 4% molybdenum and 0.04% to 0.08% palladium; Grade 21 contains15% molybdenum, 3% aluminum, 2.7% niobium, and 0.25% silicon; Grade 23contains 6% aluminum, 4% vanadium, 0.13% (maximum) Oxygen; Grade 24contains 6% aluminum, 4% vanadium and 0.04% to 0.08% palladium. Grade 25contains 6% aluminum, 4% vanadium and 0.3% to 0.8% nickel and 0.04% to0.08% palladium; Grades 26, 26H, and 27 all contain 0.08 to 0.14%ruthenium; Grade 28 contains 3% aluminum, 2.5% vanadium and 0.08 to0.14% ruthenium; Grade 29 contains 6% aluminum, 4% vanadium and 0.08 to0.14% ruthenium; Grades 30 and 31 contain 0.3% cobalt and 0.05%palladium; Grade 32 contains 5% aluminum, 1% tin, 1% zirconium, 1%vanadium, and 0.8% molybdenum; Grades 33 and 34 contain 0.4% nickel,0.015% palladium, 0.025% ruthenium, and 0.15% chromium; Grade 35contains 4.5% aluminum, 2% molybdenum, 1.6% vanadium, 0.5% iron, and0.3% silicon; Grade 36 contains 45% niobium; Grade 37 contains 1.5%aluminum; and Grade 38 contains 4% aluminum, 2.5% vanadium, and 1.5%iron. Its mechanical properties are very similar to Grade 5, but hasgood cold workability similar to grade 9. One embodiment includes aTi6Al4V composition. One embodiment includes a composition having 3-12%aluminum, 2-8% vanadium, 0.1-0.75% iron, 0.1-0.5% oxygen, and theremainder titanium. More specifically, about 6% aluminum, about 4%vanadium, about 0.25% iron, about 0.2% oxygen, and the remaindertitanium. For example, one Ti composition may include 10 to 35% Cr, 0.05to 15% Al, 0.05 to 2% Ti, 0.05 to 2% Y₂O₅, with the balance being eitherFe, Ni or Co, or an alloy consisting of 20±1.0% Cr, 4.5±0.5% Al,0.5±0.1% Y₂O₅ or ThO₂, with the balance being Fe. For example, one Ticomposition may include 15.0-23.0% Cr, 0.5-2.0% Si, 0.0-4.0% Mo,0.0-1.2% Nb, 0.0-3.0% Fe, 0.0-0.5% Ti, 0.0-0.5% Al, 0.0-0.3% Mn,0.0-0.1% Zr, 0.0-0.035% Ce, 0.005-0.025% Mg, 0.0005-0.005% B, 0.005-0.3%C, 0.0-20.0% Co, balance Ni. Sample Ti-based feedstock componentincludes 0-45% metal powder; 15-40% binder; 0-10% Polymer (e.g.,thermoplastics and thermosets); surfactant 0-3%; lubricant 0-3%;sintering aid 0-1%. Another sample Ti-based feedstock component includesabout 62% TiH2 powder as a metal powder; about 29% naphthalene as abinder; about 2.1-2.3% polymer (e.g., EVA/epoxy); about 2.3% SURFONICN-100® as a Surfactant; lubricant is 1.5% stearic acid as a ; about 0.4%silver as a sintering Aid. Examples of metal compounds include metalhydrides, such as TiH2, and intermetallics, such as TiAl and TiAl₃. Aspecific instance of an alloy includes Ti-6Al,4V, among others. Inanother embodiment, the metal powder comprises at least approximately45% of the volume of the feedstock, while in still another, it comprisesbetween approximately 54.6% and 70.0%. In addition, Ti-Al alloys mayconsists essentially of 32-38% of Al and the balance of Ti and contains0.005-0.20% of B, and the alloy which essentially consists of the abovequantities of Al and Ti and contains, in addition to the above quantityof B, up to 0.2% of C, up to 0.3% of O and/or up to 0.3% of N (providedthat O+N add up to 0.4%) and c) 0.05-3.0% of Ni and/or 0.05-3.0% of Si,and the balance of Ti.

The amount of powdered metal and binder in the feedstock may be selectedto optimize moldability while insuring acceptable green densities. Inone embodiment, the feedstock used for the metal injection moldingportion of the invention may include at least about 40 percent by weightpowdered metal, in another about 50 percent by weight powdered metal ormore. In one embodiment, the feedstock includes at least about 60percent by weight powdered metal, preferably about 65 percent by weightor more powdered metal. In yet another embodiment, the feedstockincludes at least about 75 percent by weight powdered metal. In yetanother embodiment, the feedstock includes at least about 80 percent byweight powdered metal. In yet another embodiment, the feedstock includesat least about 85 percent by weight powdered metal. In yet anotherembodiment, the feedstock includes at least about 90 percent by weightpowdered metal.

The binding agent may be any suitable binding agent that does notdestroy or interfere with the powdered metals. The binder may be presentin an amount of about 50 percent or less by weight of the feedstock. Inone embodiment, the binder is present in an amount ranging from 10percent to about 50 percent by weight. In another embodiment, the binderis present in an amount of about 25 percent to about 50 percent byweight of the feedstock. In another embodiment, the binder is present inan amount of about 30 percent to about 40 percent by weight of thefeedstock. In one embodiment, the binder is an aqueous binder. Inanother embodiment, the binder is an organic-based binder. Examples ofbinders include, but are not limited to, thermoplastic resins, waxes,and combinations thereof. Non-limiting examples of thermoplastic resinsinclude polyolefins such as acrylic polyethylene, polypropylene,polystyrene, polyvinyl chloride, polyethylene carbonate, polyethyleneglycol, and mixtures thereof. Suitable waxes include, but are notlimited to, microcrystalline wax, bee wax, synthetic wax, andcombinations thereof.

Examples of suitable powdered metals for use in the feedstock include,but are not limited to: stainless steel including martensitic andaustenitic stainless steel, steel alloys, tungsten alloys, soft magneticalloys such as iron, iron-silicon, electrical steel, iron-nickel(50Ni-50F3), low thermal expansion alloys, or combinations thereof. Inone embodiment, the powdered metal is a mixture of stainless steel,brass and tungsten alloy. The stainless steel used in the presentinvention may be any 1 series carbon steels, 2 series nickel steels, 3series nickel-chromium steels, 4 series molybdenum steels, serieschromium steels, 6 series chromium-vanadium steels, 7 series tungstensteels, 8 series nickel-chromium-molybdenum steels, or 9 seriessilicon-manganese steels, e.g., 102, 174, 201, 202, 300, 302, 303, 304,308, 309, 316, 316L, 316Ti, 321, 405, 408, 409, 410, 416, 420, 430, 439,440, 446 or 601-665 grade stainless steel.

As known to those of ordinary skill in the art, stainless steel is analloy of iron and at least one other component that imparts corrosionresistance. As such, in one embodiment, the stainless steel is an alloyof iron and at least one of chromium, nickel, silicon, molybdenum, ormixtures thereof. Examples of such alloys include, but are not limitedto, an alloy containing about 1.5 to about 2.5 percent nickel, no morethan about 0.5 percent molybdenum, no more than about 0.15 percentcarbon, and the balance iron with a density ranging from about 7 g/cm³to about 8 g/cm³; an alloy containing about 6 to about 8 percent nickel,no more than about 0.5 percent molybdenum, no more than about 0.15percent carbon, and the balance iron with a density ranging from about 7g/cm³ to about 8 g/cm³; an alloy containing about 0.5 to about 1 percentchromium, about 0.5 percent to about 1 percent nickel, no more thanabout 0.5 percent molybdenum, no more than about 0.2 percent carbon, andthe balance iron with a density ranging from about 7 g/cm³ to about 8 g/cm³; an alloy containing about 2 to about 3 percent nickel, no more thanabout 0.5 percent molybdenum, about 0.3 to about 0.6 percent carbon, andthe balance iron with a density ranging from about 7 g/cm³ to about 8g/cm³; an alloy containing about 6 to about 8 percent nickel, no morethan about 0.5 percent molybdenum, about 0.2 to about 0.5 percentcarbon, and the balance iron with a density ranging from about 7 g/cm³to about 8 g/cm³; an alloy containing about 1 to about 1.6 percentchromium, about 0.5 percent or less nickel, no more than about 0.5percent molybdenum, about 0.9 to about 1.2 percent carbon, and thebalance iron with a density ranging from about 7 g/cm³ to about 8 g/cm³;and combinations thereof.

Suitable tungsten alloys include an alloy containing about 2.5 to about3.5 percent nickel, about 0.5 percent to about 2.5 percent copper oriron, and the balance tungsten with a density ranging from about 17.5g/cm³ to about 18.5 g/cm³; about 3 to about 4 percent nickel, about 94percent tungsten, and the balance copper or iron with a density rangingfrom about 17.5 g/cm³ to about 18.5 g/cm³; and mixtures thereof.

In addition, the binders may contain additives such as antioxidants,coupling agents, surfactants, elasticizing agents, dispersants, andlubricants as disclosed in U.S. Pat. No. 5,950,063, which is herebyincorporated by reference in its entirety. Suitable examples ofantioxidants include, but are not limited to thermal stabilizers, metaldeactivators, or combinations thereof. In one embodiment, the binderincludes about 0.1 to about 2.5 percent by weight of the binder of anantioxidant. Coupling agents may include but are not limited totitanate, aluminate, silane, or combinations thereof. Typical levelsrange between 0.5 and 15% by weight of the binder.

The polymeric and composite casing components may be injection molded.Polymeric materials for the bullet-end and middle body components musthave propellant compatibility and resistance to gun cleaning solventsand grease, as well as resistance to chemical, biological andradiological agents. The polymeric materials must have a temperatureresistance higher than the cook-off temperature of the propellant,typically about 320° F. The polymeric materials must haveelongation-to-break values that to resist deformation under interiorballistic pressure as high as 60,000 psi in all environments(temperatures from about −65 to about 320° F. and humidity from 0 to100% relative humidity). According to one embodiment, the middle bodycomponent is either molded onto or snap-fit to the casing head-endcomponent after which the bullet-end component is snap-fit orinterference fit to the middle body component. The components may beformed from high-strength polymer, composite or ceramic.

Examples of suitable high strength polymers include composite polymermaterial including a tungsten metal powder, nylon 6/6, nylon 6, andglass fibers; and a specific gravity in a range of 3-10. The tungstenmetal powder may be 50%-96% of a weight of the bullet body. The polymermaterial also includes about 0.5-15%, preferably about 1-12%, and mostpreferably about 2-9% by weight, of nylon 6/6, about 0.5-15%, preferablyabout 1-12%, and most preferably about 2-9% by weight, of nylon 6, andabout 0.5-15%, preferably about 1-12%, and most preferably about 2-9% byweight, of glass fibers. It is most suitable that each of theseingredients be included in amounts less than 10% by weight. Thecartridge casing body may be made of a modified ZYTEL® resin, availablefrom E.I. DuPont De Nemours Co., a modified 612 nylon resin, modified toincrease elastic response.

Examples of suitable polymers include polyurethane prepolymer,cellulose, fluoro-polymer, ethylene inter-polymer alloy elastomer,ethylene vinyl acetate, nylon, polyether imide, polyester elastomer,polyester sulfone, polyphenyl amide, polypropylene, polyvinylidenefluoride or thermoset polyurea elastomer, acrylics, homopolymers,acetates, copolymers, acrylonitrile-butadinen-styrene, thermoplasticfluoro polymers, inomers, polyamides, polyamide-imides, polyacrylates,polyatherketones, polyaryl-sulfones, polybenzimidazoles, polycarbonates,polybutylene, terephthalates, polyether imides, polyether sulfones,thermoplastic polyimides, thermoplastic polyurethanes, polyphenylenesulfides, polyethylene, polypropylene, polysulfones, polyvinylchlorides,styrene acrylonitriles, polystyrenes, polyphenylene, ether blends,styrene maleic anhydrides, polycarbonates, allyls, aminos, cyanates,epoxies, phenolics, unsaturated polyesters, bismaleimides,polyurethanes, silicones, vinylesters, or urethane hybrids. Examples ofsuitable polymers also include aliphatic or aromatic polyamide,polyeitherimide, polysulfone, polyphenylsulfone, poly-phenylene oxide,liquid crystalline polymer and polyketone. Examples of suitablecomposites include polymers such as polyphenylsulfone reinforced withbetween about 30 and about 70 weight percent, and preferably up to about65 weight percent of one or more reinforcing materials selected fromglass fiber, ceramic fiber, carbon fiber, mineral fillers, organonanoclay, or carbon nanotube. Preferred reinforcing materials, such aschopped surface-treated E-glass fibers provide flow characteristics atthe above-described loadings comparable to unfilled polymers to providea desirable combination of strength and flow characteristics that permitthe molding of head-end components. Composite components can be formedby machining or injection molding. Finally, the cartridge case mustretain sufficient joint strength at cook-off temperatures. Morespecifically, polymers suitable for molding of the projectile-endcomponent have one or more of the following properties: Yield or tensilestrength at −65° F.>10,000 psi Elongation-to-break at −65° F.>15% Yieldor tensile strength at 73° F.>8,000 psi Elongation-to-break at 73°F.>50% Yield or tensile strength at 320° F.>4,000 psiElongation-to-break at 320° F.>80%. Polymers suitable for molding of themiddle-body component have one or more of the following properties:Yield or tensile strength at −65° F.>10,000 psi Yield or tensilestrength at 73° F.>8,000 psi Yield or tensile strength at 320° F.>4,000psi.

Commercially available polymers suitable for use in the presentinvention thus include polyphenylsulfones; copolymers ofpolyphenylsulfones with polyether-sulfones or polysulfones; copolymersand blends of polyphenylsulfones with polysiloxanes;poly(etherimide-siloxane); copolymers and blends of polyetherimides andpolysiloxanes, and blends of polyetherimides andpoly(etherimide-siloxane) copolymers; and the like. Particularlypreferred are polyphenylsulfones and their copolymers with poly-sulfonesor polysiloxane that have high tensile strength and elongation-to-breakto sustain the deformation under high interior ballistic pressure. Suchpolymers are commercially available, for example, RADEL® R5800polyphenylesulfone from Solvay Advanced Polymers. The polymer can beformulated with up to about 10 wt % of one or more additives selectedfrom internal mold release agents, heat stabilizers, anti-static agents,colorants, impact modifiers and UV stabilizers.

The polymers of the present invention can also be used for conventionaltwo-piece metal-plastic hybrid cartridge case designs and conventionalshotgun shell designs. One example of such a design is an ammunitioncartridge with a one-piece substantially cylindrical polymeric cartridgecasing body with an open projectile-end and an end opposing theprojectile-end with a male or female coupling element; and a cylindricalmetal cartridge casing head-end component with an essentially closedbase end with a primer hole opposite an open end having a couplingelement that is a mate for the coupling element on the opposing end ofthe polymeric cartridge casing body joining the open end of the head-endcomponent to the opposing end of the polymeric cartridge casing body.The high polymer ductility permits the casing to resist breakage.

One embodiment includes a 2 cavity prototype mold having an upperportion and a base portion for a 5.56 case having a metal insertover-molded with a Nylon 6 (polymer) based material. In this embodimentthe polymer in the base includes a lip or flange to extract the casefrom the weapon. One 2-cavity prototype mold to produce the upperportion of the 5.56 case can be made using a stripper plate tool usingan Osco hot spur and two subgates per cavity. Another embodimentincludes a subsonic version, the difference from the standard and thesubsonic version is the walls are thicker thus requiring less powder.This will decrease the velocity of the bullet thus creating a subsonicround.

The extracting inserts is used to give the polymer case a tough enoughridge and groove for the weapons extractor to grab and pull the case outthe chamber of the gun. The extracting insert is made of 17-4 stainlesssteel that is hardened to 42-45 rc. The insert may be made of aluminum,brass, cooper, steel or even an engineered resin with enough tensilestrength.

The insert is over molded in an injection molded process using a nanoclay particle filled Nylon material. The inserts can be machined orstamped. In addition, an engineered resin able to withstand the demandon the insert allows injection molded and/or even transfer molded.

One of ordinary skill in the art will know that many propellant typesand weights can be used to prepare workable ammunition and that suchloads may be determined by a careful trial including initial lowquantity loading of a given propellant and the well known stepwiseincreasing of a given propellant loading until a maximum acceptable loadis achieved. Extreme care and caution is advised in evaluating newloads. The propellants available have various burn rates and must becarefully chosen so that a safe load is devised.

The components may be made of polymeric compositions, metals, ceramics,alloys, or combinations and mixtures thereof. In addition, thecomponents may be mixed and matched with one or more components beingmade of different materials. For example, the middle body component (notshown) may be polymeric; the bullet-end component 18 may be polymeric;and a substantially cylindrical insert (not shown) may be metal.Similarly, the middle body component (not shown) may be polymeric; thebullet-end component 18 may be metal; and a substantially cylindricalinsert (not shown) may be an alloy. The middle body component (notshown) may be polymeric; the bullet-end component 18 may be an alloy;and a substantially cylindrical insert (not shown) may be an alloy. Themiddle body component (not shown); the bullet-end component 18; and/orthe substantially cylindrical insert may be made of a metal that isformed by a metal injection molding process.

The molded substantially cylindrical insert 32 is then bound to themiddle body component 28. In the metal injection molding process ofmaking the substantially cylindrical insert 32 a mold is made in theshape of the substantially cylindrical insert 32 including the desiredprofile of the primer recess (not shown). The substantially cylindricalinsert 32 includes a substantially cylindrical coupling element 30extending from a bottom surface 34 that is opposite a top surface (notshown). Located in the top surface (not shown) is a primer recess (notshown) that extends toward the bottom surface 34. A primer flash hole(not shown) is located in the substantially cylindrical insert 32 andextends through the bottom surface 34 into the powder chamber 14. Thecoupling end (not shown) extends through the primer flash hole (notshown) to form an aperture coating (not shown) while retaining a passagefrom the top surface (not shown) through the bottom surface (not shown)and into the powder chamber 14 to provides support and protection aboutthe primer flash hole (not shown). When contacted the coupling end (notshown) interlocks with the substantially cylindrical coupling element30, through the coupling element 30 that extends with a taper to asmaller diameter at the tip (not shown) to form a physical interlockbetween substantially cylindrical insert 32 and middle body component28.

For example, the metal injection molding process, which generallyinvolves mixing fine metal powders with binders to form a feedstock thatis injection molded into a closed mold, may be used to form asubstantially cylindrical insert. After ejection from the mold, thebinders are chemically or thermally removed from the substantiallycylindrical insert so that the part can be sintered to high density.During the sintering process, the individual metal particlesmetallurgically bond together as material diffusion occurs to removemost of the porosity left by the removal of the binder.

The raw materials for metal injection molding are metal powders and athermoplastic binder. There are at least two Binders included in theblend, a primary binder and a secondary binder. This blended powder mixis worked into the plasticized binder at elevated temperature in akneader or shear roll extruder. The intermediate product is theso-called feedstock. It is usually granulated with granule sizes ofseveral millimeters. In metal injection molding, only the binders areheated up, and that is how the metal is carried into the mold cavity.

The two piece primer insert includes an individual upper primer insertportion and lower primer insert portion formed in various methods. Forexample, the individual upper primer insert portion may be formed bymetal injection molding, polymer injection molding, stamping, milling,molding, machining, punching, fine blanking, smelting, or any othermethod. The lower primer insert portion may be formed by metal injectionmolding, polymer injection molding, stamping, milling, molding,machining, punching, fine blanking, smelting, or any other method thatwill form insert portions.

The individual upper primer insert portion may be formed from anymaterial, any metal, any alloy, any plastic, any polymer or anycomposition known to the skilled artisan or listed herein. Theindividual lower primer insert portion may be formed from any material,any metal, any alloy, any plastic, any polymer or any composition knownto the skilled artisan or listed herein.

The individual upper primer insert portion may be formed from entirelyor in part from a copolymer of polylactic acid and polycarbonate, theconcentration polylactic acid may be between 5-97% and the polycarbonatemay be between 5-97%. The 5-97% is meant to be inclusive and include allpercentages between 5 and 97 including fractional increments thereof,e.g., 5, 5.25, 5.5, 6, 6.75, 7, 7.4, 8, 8.9, 9, 10 15, 20, 25, 30, 35,40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 97. In addition, thecopolymer may include other polymers, additives, fibers, nanoclay,metals etc. When other polymers are present the combined percentage ofpolylactic acid and polycarbonate may be 5, 6, 7, 8, 9, 10 15, 20, 25,30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100.

The description of the preferred embodiments should be taken asillustrating, rather than as limiting, the present invention as definedby the claims. As will be readily appreciated, numerous combinations ofthe features set forth above can be utilized without departing from thepresent invention as set forth in the claims. Such variations are notregarded as a departure from the spirit and scope of the invention, andall such modifications are intended to be included within the scope ofthe following claims.

It is contemplated that any embodiment discussed in this specificationcan be implemented with respect to any method, kit, reagent, orcomposition of the invention, and vice versa. Furthermore, compositionsof the invention can be used to achieve methods of the invention.

It will be understood that particular embodiments described herein areshown by way of illustration and not as limitations of the invention.The principal features of this invention can be employed in variousembodiments without departing from the scope of the invention. Thoseskilled in the art will recognize, or be able to ascertain using no morethan routine experimentation, numerous equivalents to the specificprocedures described herein. Such equivalents are considered to bewithin the scope of this invention and are covered by the claims.

All publications and patent applications mentioned in the specificationare indicative of the level of skill of those skilled in the art towhich this invention pertains. All publications and patent applicationsare herein incorporated by reference to the same extent as if eachindividual publication or patent application was specifically andindividually indicated to be incorporated by reference.

The use of the word “a” or “an” when used in conjunction with the term“comprising” in the claims and/or the specification may mean “one,” butit is also consistent with the meaning of “one or more,” “at least one,”and “one or more than one.” The use of the term “or” in the claims isused to mean “and/or” unless explicitly indicated to refer toalternatives only or the alternatives are mutually exclusive, althoughthe disclosure supports a definition that refers to only alternativesand “and/or.” Throughout this application, the term “about” is used toindicate that a value includes the inherent variation of error for thedevice, the method being employed to determine the value, or thevariation that exists among the study subjects.

As used in this specification and claim(s), the words “comprising” (andany form of comprising, such as “comprise” and “comprises”), “having”(and any form of having, such as “have” and “has”), “including” (and anyform of including, such as “includes” and “include”) or “containing”(and any form of containing, such as “contains” and “contain”) areinclusive or open-ended and do not exclude additional, unrecitedelements or method steps.

The term “or combinations thereof” as used herein refers to allpermutations and combinations of the listed items preceding the term.For example, “A, B, C, or combinations thereof” is intended to includeat least one of: A, B, C, AB, AC, BC, or ABC, and if order is importantin a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB.Continuing with this example, expressly included are combinations thatcontain repeats of one or more item or term, such as BB, AAA, AB, BBC,AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan willunderstand that typically there is no limit on the number of items orterms in any combination, unless otherwise apparent from the context.

All of the compositions and/or methods disclosed and claimed herein canbe made and executed without undue experimentation in light of thepresent disclosure. While the compositions and methods of this inventionhave been described in terms of preferred embodiments, it will beapparent to those of skill in the art that variations may be applied tothe compositions and/or methods and in the steps or in the sequence ofsteps of the method described herein without departing from the concept,spirit and scope of the invention. All such similar substitutes andmodifications apparent to those skilled in the art are deemed to bewithin the spirit, scope and concept of the invention as defined by theappended claims.

What is claimed is:
 1. A method of making polymer ammunition having atwo-piece primer insert comprising by the steps of: providing a twopiece primer insert (32) comprising: an upper primer insert portion (56)connected to a lower primer insert portion (58), wherein the upperprimer insert portion (56) comprises an upper primer bottom surface(34), an upper primer aperture (33) through the upper primer bottomsurface (34), and a substantially cylindrical coupling element (30)extending away from the upper primer bottom surface (34), wherein thelower primer insert portion (58) comprises: a lower primer bottomsurface (35) opposite a lower primer top surface (36), a primer recess(38) in the lower primer top surface (36) that extends toward the lowerprimer bottom surface (35) and adapted to fit a primer, a lower flashhole aperture (37) through the lower primer bottom surface (35), whereinthe lower flash hole aperture (37) is larger than the upper primeraperture (33) to form a flash hole groove (39) in the primer recess(38); providing a first polymer composition for molding a polymerammunition cartridge; molding from the first polymer composition asubstantially cylindrical polymeric middle body having the primer insertat a first end and a substantially cylindrical polymeric coupling regionat a second end, wherein the first polymer composition extends over anouter surface of the primer insert to the flange and extends over aninterior surface of the substantially cylindrical coupling region to theprimer flash hole aperture, wherein the first polymer compositionextends from the substantially cylindrical polymeric coupling region tothe primer flash hole aperture; forming a substantially cylindricalpolymeric bullet-end component from a second polymer compositioncomprising a bullet aperture opposite a polymeric bullet-end couplingthat mates to the substantially cylindrical coupling region; couplingthe substantially cylindrical coupling region to the polymericbullet-end coupling to form a propellant chamber that extends from theprimer flash hole aperture to the bullet aperture; inserting a primerinto the primer recess, wherein the primer is in operably communicationwith the propellant chamber through the primer flash hole aperture; atleast partially filling the propellant chamber with a propellant; andfrictionally fitting a projectile in the bullet-end aperture, whereinthe propellant chamber is enclosed at one end by the primer and theprojectile at the other end.
 2. The method of claim 1, wherein theinsert joint is threaded, riveted, locked, friction fitted, coined, snapfitted, chemical bonded, chemical welded, soldered, smelted, sintered,adhesive bonded, laser welded, ultrasonic welded, friction spot welded,or friction stir welded.
 3. The method of claim 1, wherein the upperprimer insert portion, the lower primer insert portion or both areformed independently by metal injection molding, polymer injectionmolding, stamping, milling, molding, machining, punching, fine blanking,smelting, or any other method that will form insert portions that may bejoined together to form a primer insert.
 4. The method of claim 1,wherein the upper primer insert portion, the lower primer insert portionor both independently comprise a polymer, a metal, an alloy, or aceramic alloy.
 5. The method of claim 4, wherein the upper primer insertportion and the lower primer insert portion comprise the same materialor different materials.
 6. The method of claim 1, wherein the upperprimer insert portion comprises a polymer, a metal, an alloy, or aceramic alloy and the lower primer insert portion comprises a differentpolymer, metal, alloy, or ceramic alloy.
 7. The method of claim 1,wherein the upper primer insert portion and the lower primer insertportion comprise steel, nickel, chromium, copper, carbon, iron,stainless steel or brass.
 8. The method of claim 1, further comprising aflash hole groove that extends circumferentially about the upper primeraperture or the lower primer aperture.
 9. The method of claim 1, whereinthe first polymer composition, the second polymer composition or bothindependently comprise a nylon polymer.
 10. The method of claim 1,wherein the first polymer composition, the second polymer composition orboth independently comprise between about 10 and about 70 wt % glassfiber fillers, mineral fillers, or mixtures thereof.
 11. The method ofclaim 1, wherein the first polymer composition, the second polymercomposition or both independently comprise polyurethane prepolymer,cellulose, fluoro-polymer, ethylene inter-polymer alloy elastomer,ethylene vinyl acetate, nylon, polyether imide, polyester elastomer,polyester sulfone, polyphenyl amide, polypropylene, polyvinylidenefluoride or thermoset polyurea elastomer, acrylics, homopolymers,acetates, copolymers, acrylonitrile-butadinen-styrene, thermoplasticfluoro polymers, inomers, polyamides, polyamide-imides, polyacrylates,polyatherketones, polyaryl-sulfones, polybenzimidazoles, polycarbonates,polybutylene, terephthalates, polyether imides, polyether sulfones,thermoplastic polyimides, thermoplastic polyurethanes, polyphenylenesulfides, polyethylene, polypropylene, polysulfones, polyvinylchlorides,styrene acrylonitriles, polystyrenes, polyphenylene, ether blends,styrene maleic anhydrides, polycarbonates, allyls, aminos, cyanates,epoxies, phenolics, unsaturated polyesters, bismaleimides,polyurethanes, silicones, vinylesters, urethane hybrids,polyphenylsulfones, copolymers of polyphenylsulfones withpolyethersulfones or polysulfones, copolymers of poly-phenylsulfoneswith siloxanes, blends of polyphenylsulfones with polysiloxanes,poly(etherimide-siloxane) copolymers, blends of polyetherimides andpolysiloxanes, and blends of polyetherimides andpoly(etherimide-siloxane) copolymers.
 12. The method of claim 1, whereinthe bullet aperture comprises one or more cannelures formed on an innercircumferential surface of the bullet aperture.
 13. The method of claim1, wherein the bullet aperture accepts a 0.221, 0.223, 0.243, 0.25-06,0.264, 0.270, 0.300, 0.308, 0.338, 0.30-30, 0.30-06, 0.45-70 or 0.50-90,50 caliber, 45 caliber, 380 caliber or 38 caliber, 5.56 mm, 6 mm, 7 mm,7.62 mm, 8 mm, 9 mm, 10 mm, 12.7 mm, 14.5 mm, 14.7 mm, 20 mm, 25 mm, 30mm, 40 mm, 57 mm, 60 mm, 75 mm, 76 mm, 81 mm, 90 mm, 100 mm, 105 mm, 106mm, 115 mm, 120 mm, 122 mm, 125 mm, 130 mm, 152 mm, 155 mm, 165 mm, 175mm, 203 mm or 460 mm, 4.2 inch or 8 inch projectile.
 14. The method ofclaim 1, wherein the projectile has a frustoconical shaped nose.
 15. Amethod of making a polymer ammunition having a two-piece primer insertcomprising by the steps of: forming a two-piece primer insert comprisingthe steps of: forming an upper primer insert portion comprising an upperprimer bottom surface, an upper primer aperture through the upper primerbottom surface; a substantially cylindrical coupling element extendingaway from the upper primer bottom surface, and an interior surfaceinside the substantially cylindrical coupling element; forming a lowerprimer insert portion comprising a lower primer bottom surface oppositea lower primer top surface, a primer recess in the lower primer topsurface that extends toward the lower primer bottom surface and adaptedto fit a primer, a lower primer aperture through the lower primer bottomsurface, and a flange that extends circumferentially about an outer edgeof the lower primer top surface, wherein the flange is adapted toreceive a polymer overmolding; aligning the upper primer bottom surfaceand the lower primer bottom surface to align the lower primer apertureto form an insert joint; linking the upper primer bottom surface and thelower primer bottom surface to form a primer insert; providing a firstpolymer composition for molding a polymer ammunition cartridge; moldingfrom the first polymer composition a substantially cylindrical polymericmiddle body having the primer insert at a first end and a substantiallycylindrical polymeric coupling region at a second end, wherein the firstpolymer composition extends over an outer surface of the primer insertto the flange and extends over an interior surface of the substantiallycylindrical coupling region to the primer flash hole aperture, whereinthe first polymer composition extends from the substantially cylindricalpolymeric coupling region to the primer flash hole aperture; forming asubstantially cylindrical polymeric bullet-end component from a secondpolymer composition comprising a bullet aperture opposite a polymericbullet-end coupling that mates to the substantially cylindrical couplingregion; coupling the substantially cylindrical coupling region to thepolymeric bullet-end coupling to form a propellant chamber that extendsfrom the primer flash hole aperture to the bullet aperture; inserting aprimer into the primer recess, wherein the primer is in operablycommunication with the propellant chamber through the primer flash holeaperture; at least partially filling the propellant chamber with apropellant; and frictionally fitting a projectile in the bullet-endaperture, wherein the propellant chamber is enclosed at one end by theprimer and the projectile at the other end.
 16. The method of claim 15,wherein the upper primer insert portion, the lower primer insert portionor both are independently formed by metal injection molding, polymerinjection molding, stamping, milling, molding, machining, punching, fineblanking, smelting, or any other method that will form insert portionsthat may be joined together to form a primer insert.
 17. The method ofclaim 15, wherein the upper primer insert portion comprises a polymer, ametal, an alloy, or a ceramic alloy and the lower primer insert portioncomprises a different polymer, metal, alloy, or ceramic alloy.
 18. Amethod of making polymer ammunition having a two-piece primer insertcomprising by the steps of: providing a two piece primer insertcomprising: an upper primer insert portion comprising an upper primerbottom surface, an upper primer aperture through the upper primer bottomsurface; a substantially cylindrical coupling element extending awayfrom the upper primer bottom surface, and an interior surface inside thesubstantially cylindrical coupling element; a lower primer insertportion comprising a lower primer bottom surface opposite a lower primertop surface, a primer recess in the lower primer top surface thatextends toward the lower primer bottom surface and adapted to fit aprimer, a lower primer aperture through the lower primer bottom surface,and a flange that extends circumferentially about an outer edge of thelower primer top surface, wherein the flange is adapted to receive apolymer overmolding; a flash hole groove that extends circumferentiallyabout the upper primer aperture or that extends circumferentially aboutthe lower primer aperture; and an insert joint that links the upperprimer bottom surface and the lower primer bottom surface to align thelower primer aperture and form a primer insert; providing a firstpolymer composition for molding a polymer ammunition cartridge; moldingfrom the first polymer composition a substantially cylindrical polymericmiddle body having the primer insert at a first end and a substantiallycylindrical polymeric coupling region at a second end, wherein the firstpolymer composition extends over an outer surface of the primer insertto the flange and extends over an interior surface of the substantiallycylindrical coupling region to the primer flash hole aperture, whereinthe first polymer composition extends from the substantially cylindricalpolymeric coupling region to the primer flash hole aperture; forming asubstantially cylindrical polymeric bullet-end component from a secondpolymer composition comprising a bullet aperture opposite a polymericbullet-end coupling that mates to the substantially cylindrical couplingregion; coupling the substantially cylindrical coupling region to thepolymeric bullet-end coupling to form a propellant chamber that extendsfrom the primer flash hole aperture to the bullet aperture; inserting aprimer into the primer recess, wherein the primer is in operablycommunication with the propellant chamber through the primer flash holeaperture; at least partially filling the propellant chamber with apropellant; and frictionally fitting a projectile in the bullet-endaperture, wherein the propellant chamber is enclosed at one end by theprimer and the projectile at the other end.
 19. The method of claim 18,wherein the upper primer insert portion, the lower primer insert portionor both are independently formed by metal injection molding, polymerinjection molding, stamping, milling, molding, machining, punching, fineblanking, smelting, or any other method that will form insert portionsthat may be joined together to form a primer insert.
 20. The method ofclaim 18, wherein the insert joint is formed by threading, riveting,locking, friction fitting, coining, snap fitting, chemical bonding,chemical welding, soldering, smelting, sintering, adhesive bonding,laser welding, ultrasonic welding, friction spot welding, friction stirwelding spin-welding, vibration-welding, ultrasonic-welding,laser-welding techniques or a combination thereof.